Paint & Coating Industry July 2011

July 2011 VOLUME 27, NUMBER 7

INSIDE Taking Semigloss Coatings Green

Paint

New-Generation Three Roll Mills

Coatings Industry

Controlled-Release IPBC

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Globally Serving Liquid and Powder Formulators and Manufacturers

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CONTENTS PA I N T & C O AT I N G S I N D U S T RY , V O L U M E 2 7 , N U M B E R 7

July 2011

FEATURES

50

ONLINE FEATURES w w w. pcimag.com Coating Protects Petrochemical Tanks and Pipes at Elevated Temperatures, SherwinWilliams Protective & Marine Coatings New Nanocomposite Barrier Coatings Provide Cost and Performance Advantages Over EVOH and PVDC, InMat High-Performance Alternative to Zinc Plating, NOF Metal Coatings North America Inc.

24 The Global Top 10 and PCI 25

High-Temperature Chromatography System Helps Researchers Develop Nanoparticle Coatings, Malvern Instruments

36 Enhanced Dry-Film Coating Performance Through Controlled-Release IPBC, ISP

New Binder Permits Up to 50% Less TiO2 for Waterborne Traffic Paints, Dow Coating Materials

40 New Vinyl Acetate Ethylene Latex Takes Semigloss Coatings Green, Forbo Bonding Systems

DEPARTMENTS

46 New-Generation Three Roll Mills Meet Today’s Challenges, Buhler AG 50 Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring, Cytec Industries 62 Expanding the Functionality of Coatings Through Chemical Microencapsulation, Encapsys Division, Appleton Papers Inc.

6 8 12 14 20 68 70

Viewpoint Industry News Calendar of Events Company News Names in the News Classifieds Advertiser Index ON THE COVER:

BUSINESS TOOLS

Cover design by Clare Johnson.

45 Green Showcases 64 Equipment Showcases

PCI - PAINT & COATINGS INDUSTRY (ISSN 0884-3848) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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V I EWPOINT

Despite Challenges, Industry Begins to Rebound This issue of PCI features the 19th annual ranking of the top coatings manufacturers in the world. Listed in the article (page 24) are the Top 10 global leaders and the Top 25 North American companies. Sales numbers listed for each company reflect worldwide 2010 global coatings sales figures. The Top 10 global companies all reported increased sales in 2010, ranging from a few percentage points to over 10 percent. Most of the increases were close to 10 percent. The picture for the Top 25 North American companies appears somewhat more mixed. While only a few companies reported decreased sales for 2010, about a third reported either flat sales or modest sales increases. However, compared with the drop in sales seen in 2009, the industry appears to be rebounding. Industry consolidation continues to play out around the world. In March 2010, The Sherwin-Williams Co. acquired the Industrial Wood Coatings business of Arch Chemicals. In June 2010, AkzoNobel finalized its purchase of Dow Powder Coatings, the former Rohm & Haas powder activities, from the Dow Chemical Co. Earlier this year, Japanese Kansai Paint Co. successfully acquired Freeworld Coatings Ltd., a South African coatings company. And in June of this year, Denmark-based Hempel announced its acquisition of decorative coatings manufacturer Crown Paints. Globalization appears to make sense in this business climate. As the global economy began to improve, demand grew in the emerging economies of Asia, Eastern Europe and South America and then moved to the more developed economies in Western Europe and the United States. In general, companies with a larger global footprint and more diverse offerings were able to recover more quickly than companies with a more narrow focus. Charles E. Bunch, Chairman and CEO of PPG Industries, commented to shareholders at the company’s annual

meeting this year on his company’s move to a more global focus, “We have continued to pursue growth in emerging regions such as Asia/Pacific, Eastern Europe and Latin America, which has broadened our reach and reduced our exposure to weaknesses in any one region.” PPG’s businesses in emerging regions grew 20 percent in 2010, he said, and with sales of nearly $3.6 billion, these regions now account for 27 percent of the company’s sales. The United States and Canada now represent less than 45 percent of PPG’s sales. Valspar’s most recent financial results illustrate another major theme in the coatings industry – price increases. While the company reported increased sales for the second quarter, net income was down, due in part to rising raw material costs. In a news releases announcing a price increase in AkzoNobel Powder Coatings’ Europe West segment, Gordon MacLeman, Managing Director of the Sub Business Unit Powder Coatings Europe West, commented on the challenges facing the industry: “These are really unprecedented times for our industry. This level of increase in purchasing cost was literally unimaginable until very recently. Unfortunately we believe we will see continued shortages, and consequently increases in our purchase cost for some considerable time to come.” Faced with rising raw material costs, companies are adjusting pricing and continuing to hold costs. Going forward, the industry is responding to the challenges of globalization, the lingering effects of the 2008 financial crisis, and rising raw material costs by continued consolidation, diversification, price adjustments and strict cost containment. While the PCI staff made every effort to seek out the top companies in the industry, we may have inadvertently omitted some. Please contact me at [email protected] if you have interest in being included next year.

By Karen Parker, Associate Editor, PCI Magazine 6

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P U B L I S H I N G / S A L E S S TA F F Senior Group Publisher

Tom A. Esposito

Publisher/ Donna M. Campbell East Coast Sales Tel: 610/650.4050 • Fax: 248/502.1091 Midwest/ West Coast Sales China Media Rep.

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E D I T O R I A L S TA F F Editor

Technical Editor Associate Editor & E-News Editor Art Director

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O P E R AT I O N S S TA F F Marketing & Promotion Coordinator Audience Development Manager Corporate Fulfillment Manager Audience Audit Coordinator Single Copy Sales List Rental Manager Reprint Manager

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Markets:

Architectural Coatings

Industrial Coatings

Container Automotive

Civil Aerospace Engineering

Coatings Technologies:

SolventBorne Coatings

WaterBorne Coatings

Powder Coatings

Surface/Substrate:

Wood

Brick

Concrete

Marine & Maintenance

UV Coatings

Metal

Stucco

High Solids Coatings

Vinyl

Plastic

Brenntag understands change is normal for the Coatings Industry. As the Coatings Industry has evolved through the years, Brenntag’s Paint and Coatings Team continues to provide our customers with the products and services to stay competitive in the marketplace. Whether you face different markets, technologies, or substrate applications, Brenntag’s Paint and Coatings Team can help you to adapt and make change work to your advantage.

Brenntag offers a complete specialty and industrial product portfolio, technical assistance with product development, formulations and applications know-how, superior logistics with versatile blending and re-packaging capabilities, and last, but not least, commitment to quality and safety. Change demands innovation and creativity. Brenntag Understands. Brenntag North America, Inc. (610) 926-6100 Ext: 3858 [email protected] brenntagnorthamerica.com

The Glocal® Chemical Distributor.

I NDUSTRY NEWS

New Recommendations Released for Occupational Exposure to Ultrafine TiO2 WASHINGTON, DC – The National Institute for Occupational Safety and Health (NIOSH) has released a new Current Intelligence Bulletin (CIB) that addresses exposure limits to ultrafine titanium dioxide. Titanium dioxide is produced and used in the workplace in varying particle-size fractions, including fine and ultrafine sizes. The NIOSH CIB reviews the animal and human data relevant to assessing the carcinogenicity and other adverse health effects of TiO2, provides a quantitative risk assessment using dose-response information from the rat and human lung dosimetry modeling, and recommends occupational exposure limits for fine and ultrafine (including engineered nanoscale) TiO2.

Additionally, it describes exposure monitoring techniques, exposure control strategies and research needs. It only addresses occupational exposures by inhalation and not nonoccupational exposures. According to the report, “NIOSH recommends exposure limits of 2.4 mg/m3

for fine TiO2 and 0.3 mg/m3 for ultrafine (including engineered nanoscale) TiO2, as time-weighted average (TWA) concentrations for up to 10 hours per day during a 40-hour work week. NIOSH has determined that ultrafine TiO2 is a potential occupational carcinogen but that there are insufficient data at this time to classify fine TiO2 as a potential occupational carcinogen. However, as a precautionary step, NIOSH used all of the animal tumor response data when conducting dose-response modeling and determining separate RELs for ultrafine and fine TiO2. These recommendations represent levels that over a working lifetime are estimated to reduce risks of lung cancer to below 1

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I NDUSTRY NEWS in 1,000. NIOSH realizes that knowledge about the health effects of nanomaterials is an evolving area of science. Therefore, NIOSH intends to continue dialogue with the scientific community and will consider any comments about nano-size titanium dioxide for future updates of this document.”

For the full report, visit http:// w w w.cdc.gov/niosh/docs /2011-160/ pdfs/2011-160.pdf.

DIY Customers Are More Satisfied With Paint Brands WESTLAKE VILLAGE, CA – According

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to the J.D. Power and Associates 2011 U.S. Interior Paint Satisfaction StudySM, do-it-yourselfers are notably more satisfied with interior paint brands in 2011 compared with 2010. The study, now in its fifth year, measures customer satisfaction among those who have purchased and applied interior paint during the past year. It examines six key factors of the painting experience: application, product offerings, durability, price, design guides, and warranty and guarantees. Overall satisfaction with interior paint brands has increased considerably to an average of 770 on a 1,000-point scale in 2011 from 754 in 2010. Satisfaction has increased in five of the six factors included in the study – all except design guides. The most notable improvements have occurred in the warranty, product offerings, application and durability factors. Benjamin Moore ranks highest in customer satisfaction with interior paint, with a score of 791. Following Benjamin Moore in the rankings are Porter (789) and Sherwin-Williams (778). “The highest performing brands in the study also benefit from the highest levels of customer loyalty,” said Christina Cooley, Senior Manager of the Real Estate and Construction Industries Practice at J.D. Power and Associates. “Among customers of some of these brands, the proportion who say they definitely will purchase the brand of paint again averages as high as 50 percent, which is considerably greater than the industry average of 36 percent.” The 2011 U.S. Interior Paint Satisfaction Study is based on responses from more than 8,900 customers who purchased and applied interior paint within the previous 12 months.

Waterborne Symposium Issues Call for Papers HATTIESBURG, MS – Organizers of The Waterborne Symposium have issued a call for papers, welcoming papers pertaining to new and emerging technologies related to materials, processes, production, characterization, application and markets in the field of surface coatings. Papers must be original and represent recent advancements in coatings science and related disciplines. The deadline for submitting abstracts is August 15, 2011. The paper submission deadline is December 2, 2011. The Waterborne Symposium will take place February 13-17, 2012, at the New Orleans Marriott, New Orleans, LA. 䡲

INNOVATION = VALUE COATINGS:

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C ALENDAR Meetings, Shows and Educational Programs JULY 13-14 Latin American Coatings Show Mexico City www.coatings-group.com 18-20 Coatings for People in the General Industry, Sales and Marketing

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24-30 19th International Conference on Composites Shanghai, China www.icce-nano.org

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10-14 Introduction to Paint Formulation Rolla, MO http://coatings.mst.edu/index.html 16-18 ASC Fall Convention Indianapolis, IN www.ascouncil.org 18-20 RadTech Europe Basel, Switzerland www.radtech-europe.com 23-26 Western Coatings Symposium Las Vegas www.pnwsct.org/symposium-wcs 24-26 Future of Pigments Berlin, Germany www.pigmentmarkets.com

NOV. 1-3 Chem Show New York City www.chemshow.com 21-23 ABRAFATI São Paulo, Brazil www.abrafati2011.com.br/index_engl.html 23-25 ChinaCoat 2011 Shanghai, China www.chinacoat.net

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C O M PANY NEWS

Dow Microbial Control Launches Facility in Australia MELBOURNE, Australia – Dow Microbial Control has opened a new Customer Application Center in Melbourne, Australia, giving customers in Australia and New Zealand access to state-ofthe-art testing laboratories and innovative formulations that are in line with local regulatory requirements. Senior management from Dow Microbial Control and customers

ROWA GROUP Opens Subsidiary in China PINNEBERG, Germany – ROWA GROUP has now set up an official subsidiary in China, ROWA Coatings, which is scheduled to begin operations in the second quarter of 2011. Headquartered in Beijing, ROWA Coatings’ initial function will be to grow the business of ROWA Lack in China and boost the ROWA brand presence. In addition, it will enable ROWA Lack to boost service quality in China, providing more responsive support to Chinese customers. Helen Li, who has successfully represented the interests of ROWA Lack in China for years, will lead the new subsidiary.

LANXESS Renames Business Unit/ Opens Office in Brussels LEVERKUSEN, Germany – LANXESS has given its Basic Chemicals business unit a new name: Advanced Industrial Intermediates. The new name establishes a direct link to the product portfolio, which includes advanced intermediates for numerous branches of industry. The company has also opened an office of its own in Brussels. Stefan Borst, previously EU Correspondent of the news magazine Focus, will head the office.

Momentive Performance Materials to Expand Joint Venture in China ALBANY, NY/JIANDE, China – Momentive Performance Materials Inc. and Zhejiang Xinan Chemical Industrial Group, a provider of agricultural chemicals and organic silicon products, announced the planned expansion of manufacturing capacity by their joint-venture company, Zhejiang Xinan Momentive Performance Materials Co. Ltd. The joint venture company’s plant in Jiande, China, which has annual production capacity of approximately 50,000 metric tons of siloxane, successfully started its first phase of operations in the fourth quarter of 2010. With the expansion, siloxane production capacity is expected to triple to an estimated 150,000 metric tons per year, commencing in 2013.

BASF Plans Dispersions Plant in South Africa DURBAN, South Africa – BASF is planning to invest in a dispersions plant in Durban, South Africa. The new plant will produce acrylic dispersions mainly for the coatings and construction 14

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JULY 2011 | W W W . P C I M A G . C O M

from various industries were present for the grand opening. The Dow Microbial Control Academy also conducted its first training courses in Australia, focusing on the latest technologies and trends in microbial control. Following the launch event, guests were invited to take part in a firsthand tour of the new facility in Altona, Melbourne.

industries. The facility will benefit from local availability of raw materials and proximity to key customers who serve South Africa and Sub Saharan Africa markets. Production is scheduled to begin in the second half of 2012.

Dow Epoxy to Expand LER Capacity in Germany MIDLAND, MI – Dow Epoxy, a business unit of The Dow Chemical Co., has announced plans to expand liquid epoxy resin (LER) capacity at its plant in Stade, Germany. This expansion will provide additional capacity as early as the fourth quarter of 2012 and will increase capacity by 30 KTA, a 10-percent increase in the company’s global LER capacity.

DSM and Interfloat Sign New Agreements GELEEN, the Netherlands – DSM Advanced Surfaces has signed license and supply agreements with Interfloat Corp., a solar glass producer, opening the way for Interfloat to start producing cover glass for solar modules coated with KhepriCoat™, a hightransmission/anti-reflective coating from DSM Advanced Surfaces. The KhepriCoat technology will be taken into production at Interfloat’s solar glass plant in Tschernitz, Germany. The transfer of know-how and technology, and the installation of the coating equipment, are expected to be completed by August, when Interfloat will start production.

Perstorp to Invest in China Facility PERSTORP, Sweden – Perstorp is investing in extended capacity for polyalcohol neopentyl glycol by establishing production at the group’s manufacturing site in Zibo, China. With planned production to start during the second half of 2012, the new capacity will be through Perstorp’s joint venture, Shandong Fufeng Perstorp Chemical Co. Ltd.

PPG to Purchase European Coatings Company PITTSBURGH – PPG Industries has signed an agreement to acquire Dyrup A/S, a European coatings company based in Copenhagen, Denmark, from its owner, Monberg & Thorsen, a public holding company. The total transaction value, including assumed debt, is around $200 million. Dyrup is a European producer of architectural coatings, in particular wood stains, and specialty products with 2010 sales of approximately €190 million ($270 million).

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Ask the Expert Charlie Hegedus Research Associate

Q

I am formulating waterborne alkyd coatings and need defoamer additives to improve my coating manufacturing, application and performance properties. What can you suggest?

Waterborne alkyd coatings are gaining popularity due to their enhanced properties, green chemistry and low VOCs. However, like most resins, waterborne alkyd coatings require specific defoamers to achieve optimal performance. Defoamers reduce or eliminate foam and help avoid production, application and applied coating problems. Our studies demonstrate that Surfy¯nol® DF-58 and DF-66 silicone defoamers (used at 0.05% to 0.5% of total formula) and Surfy¯nol DF-75 organic oil defoamer (used at 0.2% to 1%) provide excellent compatibility and defoaming. These additives enhance gloss of high-gloss coatings and provide excellent substrate coverage, appearance and protection. In wood coatings, such as clear varnishes and stains, they promote complete coverage, smooth finish, and excellent gloss, clarity and distinctness of image. In industrial coatings, such as metal primers, they eliminate defects such as pinholes, craters and other defects that can lead to corrosion, disbondment and other failures.

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C O M PA N Y NEWS AkzoNobel to Split ICI Pakistan AMSTERDAM, the Netherlands – Akzo Nobel N.V. (AkzoNobel) is seeking approval from the board and shareholders of ICI Pakistan Limited (ICI Pakistan) to separate the organization’s paints and chemicals businesses. Under the terms of the proposal, AkzoNobel would retain direct majority control of the paint business by separating it into a new legal entity, AkzoNobel Pakistan Limited, through a de-merger process approved by the Pakistani courts. Subsequently, AkzoNobel would dispose of its entire shareholding in the remainder of ICI Pakistan.

Troy Introduces Mergal® 753 WetState Preservative in Canada FLORHAM PARK, NJ – Troy Corp. announced that The Pest Management Regulatory Agency of Health Canada, in accordance with the Pest Control Products Act, has approved the usage of Mergal 753 wetstate preservative for the in-package protection of paints, coatings and allied products. Mergal 753 is a zero-VOC, formaldehydefree dispersion with broad-spectrum efficacy against bacteria, fungi and yeast.

Ashland to Acquire International Specialty Products Inc.

images from Dow exposure stations in Glen St. Mary, FL, and Geelong, Australia, are also accessible. In addition to tracking their own test formulations, Dow customers can use eXposure Vision Viewer to monitor the performance of new Dow products. North and south views are updated quarterly, and 45° south views are updated bimonthly.

OMG Americas Expands Territory of The Cary Co. CLEVELAND – OMG Americas has expanded The Cary Co.’s region in the United States. The Cary Co. will represent the OMG Borchi® line of coatings additives as well as the metal carboxylates line. The new region will include Illinois, Indiana, Wisconsin, Minnesota, North Dakota, South Dakota, Iowa and western Michigan.

Huber Engineered Materials Renames Business Unit ATLANTA – Huber Engineered Materials (HEM) is renaming its Alumina Trihydrate business unit Fire Retardant Additives. The new name more accurately reflects the vast array of non-halogen fire-retardant and smoke-suppressant technologies, brands and products now offered.

COVINGTON, KY/WAYNE, NJ – Ashland Inc. has agreed to acquire privately owned International Specialty Products Inc. (ISP), a global specialty chemical manufacturer of functional ingredients and technologies. Under the terms of the stock purchase agreement, Ashland will pay approximately $3.2 billion for the business in an allcash transaction. ISP’s advanced product portfolio will expand Ashland’s position in high-growth markets such as personal care, pharmaceutical and energy.

E.W. Kaufmann Co. Receives Cognis’ DOME Award

Dow Coating Materials Launches eXposure Vision™ Viewer

Sherwin-Williams Renames Chemical Coatings Division

PHILADELPHIA – Dow Coating Materials has launched eXposure Vision™ Viewer, an on-line system that puts exposure station test panels within easy view. Through a secured login Web site, eXposure Vision Viewer gives Dow customers access to test panel images in high resolution. Updated images are posted bimonthly and archived for future reference and comparison. Dow customers can track test panels under evaluation at Dow’s largest exposure station, located in Spring House, PA. Selected test panel

CLEVELAND – Sherwin-Williams announced that its Chemical Coatings Division has been renamed Product Finishes. Following the acquisitions of industrial wood finishing leaders Becker Acroma and Sayerlack in 2010, the newly expanded Sherwin-Williams Product Finishes Division now boasts a very strong presence in Europe, adding significant manufacturing and distribution capabilities. These acquisitions also added to the company’s existing infrastructure in China and Asia, doubling its capabilities.

JULY 2011 | W W W . P C I M A G . C O M

BRISTOL, PA – Cognis Corp. (now part of BASF) has recognized E.W. Kaufmann Co., a raw materials distributor to the coatings, plastics, ink, construction and adhesives industries, with its Distributor Operational Measure of Excellence (DOME) award. The award was presented in recognition of E.W. Kaufmann Co.’s significant achievements in sales growth and exceptional service.

The new Z-line of performance additives aims to provide improvements to customers developing environmentally sustainable green coatings. As the demand for "green" coatings continues to rise at a furious pace, Troy’s Z-line offers formulators enhanced performance in making greener coatings possible without adding undesirable components such as VOCs or HAP’s. With the Z designed products, Troy continues its commitment to assist industry in addressing the need for performance products that are environmentally responsible and yet economically viable. Contact your Troy Sales Representative for information on the Z-line of Troy performance additives or visit www.troycorp.com.

Troy Corporation, 8 Vreeland Road, Florham Park, New Jersey USA 07932 • Telephone: +1 973-443-4200 • Fax: +1 973-443-0258

C O M PANY NEWS Evonik Finalizes Purchase of hanse chemie Group ESSEN, Germany – Evonik Industries has completed the purchase of the hanse chemie Group, comprising hanse chemie AG and nanoresins AG. With a workforce of some 100 employees, the

group is headquartered in Geesthacht near Hamburg, Germany, where it produces high-quality components and raw materials for the manufacture of sealants and adhesives, molding and casting compounds, and other products. The greatest share of business will be incor-

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porated into Evonik’s Interface & Performance Business Line.

AkzoNobel Opens New Research Laboratory AMSTERDAM, the Netherlands – AkzoNobel has opened a new research laboratory in Deventer, the Netherlands. Housing more than 200 researchers from the company’s Research, Development and Innovation (RD&I) organization, the facility is one of a network of six global RD&I centers.

ALTANA Acquires Color Chemie WESEL, Germany – The specialty chemicals Group ALTANA has signed an agreement to acquire the Color Chemie Group. The chemical company, headquartered in Büdingen, Hesse, Germany, mainly produces environmentally friendly, waterbased specialty printing inks and offers related services to its customers.

Hempel to Invest in Paint Production Facility in Russia LYNGBY, Denmark – Hempel has signed an agreement with local government officials in the Russian Ulyanovsk region for Hempel Group’s first Russian paint production facility. The €23-million turnkey project will be built close to the city of Ulyanovsk, 893 kilometers east of Moscow. Scheduled to start production in December 2012, the plant will help meet growing demand for Hempel coatings in the Russian market.

,iޘœ`ÃʈÝiÀÃÊ`œÊ̅ÀiiÊ̅ˆ˜}ÃÊLiÌÌiÀIÊ̅>˜Ê>˜Þʜ̅iÀʓˆÝiÀÃ°Ê 7…ˆV…Ê“i>˜ÃÊޜÕÊV>˜Ê`œÊ̅ÀiiÊ̅ˆ˜}ÃÊLiÌÌiÀÊo UʈÝÊۈÃVœÕÃÊ«Àœ`ÕVÌÃÊv>ÃÌiÀ UÊ>ÛiʏiÃÃÊ«Àœ`ÕVÌÊÜ>ÃÌiÊ UʘVÀi>ÃiÊޜÕÀÊ«ÀœwÌ /…iÊ Õ>Ê-…>vÌʈÝiÀʈÃÊ«œÜiÀvՏ]ÊivwVˆi˜ÌÊ>˜`ÊÛiÀÃ>̈i°ÊÌÊ Vœ“Lˆ˜iÃÊ>ʏœÜ‡Ã«ii`ʅiˆV>ÊL>`iÊ>}ˆÌ>̜ÀÊ܈̅Ê>ʅˆ}…‡Ã«ii`Ê `ˆÃ«iÀÃiÀÊL>`iÊ̜ʫÀœÛˆ`iʜ«Ìˆ“Õ“ÊL>ÌV…ÊÌÕÀ˜œÛiÀ°ÊÌʅi«Ã iˆ“ˆ˜>ÌiʅœÌʜÀÊVœ`ÊëœÌÃʈ˜ÊÌi“«iÀ>ÌÕÀiÊVœ˜ÌÀœi`Ê«ÀœViÃÃiÃÊ >˜`Ê«ÀœÛˆ`iÃÊ}Ài>ÌiÀÊVœ˜ÌÀœÊœvÊۈÃVœÃˆÌÞ]Ê«>À̈ViÊÈâi]ÊVœœÀÊ >˜`ʜ̅iÀʵÕ>ˆÌˆiÃÊ>vviVÌi`ÊLÞÊ̅iʓˆÝˆ˜}Ê«ÀœViÃð

Pump Solutions Group Acquires EnviroGear® Product Line GRAND TERRACE, CA – Pump Solutions Group™ has acquired the EnviroGear product line. EnviroGear operations and manufacturing are now based in Grand Terrace, CA. Product lines include: EnviroGear, a mag-drive internal gear pump; EnviroBase™ gear pump base plate assemblies; and EnviroCare™, a line of pump and motor protection and control products. 䡲

IiÌÊLiÌÌiÀʓˆÝˆ˜}ÊÀiÃՏÌðÊiÌÊ,iޘœ`ÃÊ ˆ˜Ê̅iʈÝÒÊpʈ˜VÀi>ÃiÊ«Àœ`ÕV̈œ˜Ê >˜`Êiˆ“ˆ˜>ÌiÊÜ>ÃÌiÊLiÌÌiÀÊ̅>˜Ê>˜ÞÊ œÌ…iÀʓˆÝiÀ°Ê UÊ*Àœ`ÕViÊ>ÊVœ˜ÃˆÃÌi˜ÌÊ«Àœ`ÕVÌÊ UÊ*ÀœViÃÃÊv>ÃÌiÀÊ UÊ*ÀœÛˆ`iÊ>ÊLiÌÌiÀʅi>ÌÊÌÀ>˜ÃviÀÊVœivwVˆi˜Ì

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N AMES IN THE NEWS 䡲 Robert Carroll III, President of R.E. Carroll

Thomas Frungillo to Vice President of Sales, Latin America and Focus Markets.

Inc., has been honored as Executive of the Year

by Biltmore’s Who’s Who for 2011-2012.

䡲 Sasol Chief Executive Pat Davies has been awarded an Institution of Chemical Engineers honorary fellowship.

䡲 Sea-Land Chemical Co.

has assigned Mark Christeon the responsibility of leading the sales organization. He will be managing the Sales Team Leaders and will focus on improving sales Dauber efforts. Craig Lundell has taken on the new position of Team Leader, Supplier Relations. Kelly Kuhar has been hired as the Administrative Assistant II, providing additional support to the Procurement Department.

䡲 Lori Hilson Cioromski, President of TH Hilson Co., has received the Member of the Year Award from the National Association of Women Business Owners (NAWBO), Chicago.

Greger has named Gary Danowski Vice President, Automotive Refinish, EMEA (Europe, Middle East and Africa). Richard A. Beuke, Vice President, Silicas, has been named Vice President, Flat Glass. Kevin D. Braun, General Manager, Architectural Coatings, ANZ (Australia and New Zealand), has been named General Manager, Silica Products.

䡲 PPG Industries

䡲 Camfil Farr Air Pollution Control has promoted John Dauber to the position of Vice President of Sales, USA and Canada, and

Frungillo

䡲 DKSH’s Business Unit Performance Materials has appointed Mathias Greger to head its North American operation. Greger will focus on overall growth activities in the North American market.

䡲 DYMAX Corp. has appointed Gilberto Poinsot as a Territory Sales Manager in the Field Sales Department. Poinsot will help manufacturers in the southwest United States reduce manufacturing costs. The company has also appointed Brian Scully Inside Sales Manager in the Customer Support Department. Scully will manage and grow the global customer service and inside sales team at DYMAX. 䡲 BASF Automotive Refinish

has named Jeff Wildman a Regional Manager. He will report directly to Nick Maloof, Central Zone Manager for BASF Automotive Refinish.

䡲 Archway Sales Inc. has hired Ginny Yost as the Accounts Payable Clerk. Yost will be based out of St. Louis, MO. 䡲

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GLOBAL

TOP 10

By Karen Parker, Associate Editor, PCI Magazine

1. Akzo Nobel nv Amsterdam, the Netherlands +31 20 502 7833 www.akzonobel.com Chairman of the Board of Management: Hans Wijers Coatings Sales: $13.1 billion (€9.8 billion) AkzoNobel is the largest global coatings company and a major producer of specialty chemicals. AkzoNobel is a Global Fortune 500 company and is consistently ranked as one of the leaders in the area of sustainability. The company has operations in more than 80 countries and employs 55,000 people around the world. AkzoNobel coatings brands include global and household names such as International®, Sikkens®, Glidden®, Dulux®, Crown®, Interpon®, Levis®, Coral® and Sadolin®. Parent company: AkzoNobel Source: AkzoNobel Report 2010, press releases, company contact Recent Acquisitions and Divestments: AkzoNobel acquired Lindgens Metal Decorative Coatings and Inks in July 2010. In September 2010, the company acquired Changzhou Prime Automotive Paint Co. Ltd. The company also completed the acquisition of the former Rohm & Haas powder activities from the Dow Chemical Co. Notes: Decorative Paints signed a deal with Walmart to become the retailer’s primary paint supplier in the United States, and Dulux Trade won the contract to paint the London 2012 Olympic Games site. AkzoNobel's ambitious growth plans for Asia were underlined when the company announced that it plans to double its current revenue in China within five years. A target of $3 billion has been set for 2015, with China poised to play an integral role in AkzoNobel's strategic focus on the world's growth regions.

2. PPG Industries, Inc. Pittsburgh 412/434.3131 www.ppg.com Chairman/CEO: Charles E. Bunch Coatings Sales: Approx. $9.86 billion PPG’s global coatings businesses comprise coatings for the aerospace, architectural, automotive OEM, automotive refinish, industrial, packaging, and protective and marine markets. The company serves customers in industrial, transportation, consumer products, and construction markets and aftermarkets. PPG is the world’s leading manufacturer of transportation OEM and refinish coatings, as well as a technology leader in coatings for the wood-flooring industry and a leader in the supply of paints for consumer electronics. In 2010, PPG’s businesses in emerging regions grew 20 percent, and sales in those regions accounted for about 27 percent of the company’s total. Notably, PPG’s business in the Asia-Pacific region posted record earnings for 2010 and now represents about 15 percent of PPG’s global revenue, and PPG is now the second-largest coatings company in the Asia-Pacific region. Also in 2010, sales for the company’s Industrial Coatings segment, including the automotive OEM, industrial and packaging coatings businesses, increased $640 million or 21 percent. Coatings represented about 73 percent of PPG’s 2010 total net sales of $13.4 billion. Source: 2010 Annual Report, company website, company contact Notes: In October 2010, PPG reached an agreement to acquire Bairun, a privately held packaging coatings company in southern China. In May of this year, PPG signed an agreement to acquire Dyrup A/S, a European coatings company based in Copenhagen. Dyrup is a European producer of architectural coatings, in particular wood stains, and specialty products. PPG broke ground on its first Chinese resin-production facility in Zhangjiagang in 2009. In 2010, the largest PPG plant in Asia, PPG Coatings (Tianjin) Co. Ltd., began a two-phase project to expand its waterborne automotive and industrial coatings capacity, which is 24

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JULY 2011 | W W W . P C I M A G . C O M

expected to be about 10,000 tons annually upon project completion. PPG also strengthened its presence in Russia in June 2010, by opening an automotive refinish coatings training center in Moscow. In South Africa, PPG became the only Johannesburg-based packaging coatings supplier when it opened a packaging coatings facility inside its Prominent Paints factory there. In January 2011, PPG announced plans to expand its 14-year relationship with Asian Paints Ltd. to grow the companies’ joint coatings business in India.

3. Sherwin-Williams Co. Cleveland 216/566.2000 www.sherwin.com Chairman/CEO: Christopher M. Connor Coatings Sales: Approx. $5.83 billion The Sherwin-Williams Co. is engaged in the manufacture, distribution and sale of coatings and related products to professional, industrial, commercial and retail customers primarily in North and South America. The company has three operating segments: Paint Stores Group, Consumer Group and Global Group. All three reportable operating segments achieved organic sales growth in 2010. Net sales for the Global Finishes Group increased 26.5 percent to $2.09 billion in 2010. Net sales for the Paint Stores Group increased 4.1 percent to $4.38 billion, and external net sales for the Consumer Group increased 5.9 percent to $1.30 billion. Consolidated net sales for the entire company increased by $682 million, or 9.6 percent, to $7.776 billion. It is estimated that between 70 to 75 percent of sales, or about $5.83 billion, represents coatings sales, with the remainder being related products, including wallcoverings, floor coverings and application supplies. Sherwin-Williams has company-operated stores in all 50 states, Canada and some countries in Latin America. In 2010, the company opened 49 stores in new markets and consolidated an additional 13 redundant store locations, for a net increase of 36 new stores for the year. The company’s store count in the United States, Canada and the Caribbean now stands at 3,390. The company manufactures and sells coatings such as Dutch Boy®, Pratt & Lambert®, Martin-Senour®, Dupli-Color®, Krylon®, Thompson’s® and Minwax®, plus private-label brands to independent dealers, mass merchandisers and home-improvement centers. Sherwin-Williams produces coatings for original equipment manufacturers in a number of industries and special-purpose coatings for the automotive-aftermarket, industrialmaintenance and traffic-paint markets. Source: 2010 Annual Report, company Web site, press releases Notes: In September 2010, the company acquired Becker Industrial Products AB, a subsidiary of Sweden-based AB Wilh. In March 2010, the company acquired the Industrial Wood Coatings business of Arch Chemicals Inc.

4. DuPont Performance Coatings Wilmington, DE 302/774.1000 www.dupont.com Chairman/CEO: Ellen J. Kullman President: John McCool Coatings Sales: $3.8 billion DuPont Performance Coatings includes its core markets of automotive, collision repair and industrial coatings. The company offers high-performance liquid and powder coatings as well as high-performance specialty products. Sales of $3.8 billion were up 11 percent when compared to the prior year, reflecting a 9 percent higher volume and a 2 percent increase in selling prices. Parent Company: DuPont Source: Dupont 2010 Annual Report, company Web site Notes: In 2010, DuPont opened a research and development facility dedicated to coatings science at the Experimental Station in

Wilmington, DE. The new Coatings Technology Center (CTC) focuses on DuPont Refinish Systems products that support the automotive collision industry and DuPont Industrial Coating Solutions. Also in 2010, DuPont entered into a marketing agreement with Ecolab Inc. to commercialize new antimicrobial coating technologies for the food and beverage processing industry.

5. BASF Coatings Münster, Germany +0049 25 01 140 www.basf-coatings.com CEO/President: Raimar Jahn Coatings Sales: $3.5 billion (€2.577 billion) BASF Coatings GmbH is part of the BASF Group’s internationally operating Coatings Division. BASF Coatings develops, produces and markets a range of automotive OEM coatings, automotive refinishes, industrial coatings and decorative paints. BASF’s architectural coatings activities are based in Europe and South America. The company has been the market leader in Brazil for many years under the Suvinil brand. With the integration of the RELIUS Group in 2007, BASF Coatings now offers construction paints for interior and exterior applications and external wall insulation systems in Europe. Parent Company: BASF SE Source: Company contact, press releases Notes: In 2010, BASF Coatings GmbH and Henkel AG & Co KGaA signed a joint-venture agreement to develop corrosion-protection solutions for the automotive industry. In March 2011, BASF received the General Motors’ Supplier of the Year Award for 2010. The award has been given to BASF seven times in the last nine years, recognizing the coatings supplier for excellence in the areas of quality, service, technology and price.

6. The Valspar Corp. Minneapolis 612/851.7000 www.valspar.com CEO: Gary E. Hendrickson Coatings Sales: $2.99 billion Valspar experienced a total sales increase of approximately 10 percent in 2010. The company operates its coatings-related businesses in two reportable segments: Paints and Coatings. Sales in the Paints segment increased 8.4 percent (2010 revenue of $ 1,176.8 million) and 11.7 percent in the Coatings segment (2010 revenue of $ 1,814.8 million), for total coatings sales of $2,992 million. Source: 2010 Annual Report, company Web site Notes: In September 2010, Valspar acquired Australian paint manufacturer Wattyl Limited. In February 2011, Valspar announced the acquisition of Brazilian company Isocoat Tintas e Vernizes Ltda., a manufacturer of powder coatings used in appliance, building products, transportation and other general industrial markets.

7. Nippon Paint Co. Osaka, Japan +81.6.64581111 www.nipponpaint.com President: Kenji Sakai Coatings Sales: $2.4 billion Nippon Paint produces coatings for the automotive market, the marine coatings market, as well as industrial products. It also makes paints for residential and commercial buildings and for the do-it-yourself market. Nippon Paint’s manufacturing operations are located principally in Asia, but the company also has facilities in North America and Europe. In the United States, it has two subsidiaries that manufacture and sell paints: NB Coatings (liquid automotive coatings for plastic) and NPA Coatings (automotive body coatings and powder coatings). Source: Company contact

8. Kansai Paint Co., Ltd. Osaka, Japan +81.6.6203 5531

www.kansai.co.jp President: Shoju Kobayashi Coatings Sales: $2.38 billion for fiscal year ended March 31, 2010 Kansai Paint Co., Ltd. is a manufacturer of coatings used in Japan, Europe and the Americas, as well as China, India and other Asian countries. Core business areas include Automotive Coatings, Industrial Coatings, Decorative Coatings, and Marine and Protective Coatings. Source: Annual Report Notes: In April of this year, the board of South Africa-based Freeworld Coatings accepted Kansai Paint’s takeover offer. Freeworld Coatings manufactures and markets decorative, industrial and automotive coatings. Markets include South Africa and other parts of sub-Saharan Africa.

9. RPM International Inc. Medina, OH 330/273.5090 www.rpminc.com Chairman/CEO/President: Frank C. Sullivan Coatings Sales: $2.3 billion for fiscal year ended May 31, 2010 RPM is a holding company with subsidiaries that are leaders in specialty coatings, sealants, building materials and related services serving both industrial and consumer markets. Industrial products include corrosion-control coatings, flooring coatings and specialty chemicals. Major industrial brands are Stonhard, Tremco, illbruck, Carboline, Flowcrete, Universal Sealants and Euco. RPM’s consumer products are used by professionals and do-it-yourselfers for home maintenance and improvement, boat repair and maintenance, and by hobbyists. Consumer brands include Zinsser, Rust-Oleum, DAP, Varathane and Testors. Subsidiaries: A/D Fire, Alteco Technik, Ascoat Contracting, Carboline, Chemtec Chemicals, Dane Color, DAP, DAP Canada, Ecoloc, Euclid Admixture, Euclid Chemical, Eucomex, Fibergrate, Fibregrid, Flowcrete, Hummervoll, Increte Systems, Mantrose-Haeuser, Martin Mathys, Modern Masters, New Parks, Paramount Technical, Productos Cave, Productos de DAP, Radiant Color, Republic Powdered Metals, RPM Building Solutions Group Europe, RPM/Belgium, RustOleum, Rust-Oleum Argentina, Rust-Oleum Canada, Rust-Oleum Japan, Rust-Oleum Netherlands, Stonhard, Testor, Tor Coatings, Toxement, Tremco Barrier Solutions, Tremco illbruck, Tremco Inc., Universal Sealants, Vandex, Watco, Weatherproofing Technologies, Wolman and Zinsser. Parent Company: RPM International Inc. Source: Company contact, 2010 Annual Report, press releases Notes: Recent transactions include the Performance Coatings Group’s acquisition of Norwegian business Hummervoll Industribelegg AS in June 2010, the Building Solutions Group’s acquisition of Turkish distributor Park Dis Ticaret A.S. in September 2010, the Performance Coatings Group’s acquisition of UK-based Pipeline & Drainage Systems Ltd. in December 2010, and Euclid Chemical Co.’s acquisition of Georgia-based PSI Packaging Inc. in February 2011.

10. Jotun Sandefjord, Norway 47.33.45.70.00 www.jotun.com President/CEO: Morten Fon Coatings Sales: $2 billion The Jotun Group is a leading manufacturer of paint, coatings and powder coatings. It consists of four divisions: Jotun Dekorativ, responsible for Jotun’s decorative paints, stains and varnish deliveries in Scandinavia; Jotun Paints, responsible for decorative paints in markets outside Scandinavia; Jotun Coatings, a global segment responsible for marine protective coatings and decorative paints in local European and selected Asian markets; and Jotun Powder Coatings, responsible for powder coatings. Source: 2010 Annual Report, company Web site Notes: In November 2010, Jotun Powder Coatings launched its first furniture powder coatings range, Era-Coat MDF, a brand of powder coatings especially created for designers and furniture makers. PA I N T & C O A T I N G S I N D U S T R Y

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1. PPG Industries Inc. Pittsburgh Coatings Sales: Approx. $9.86 billion

2. Sherwin-Williams Co. Cleveland Coatings Sales: Approx. $5.83 billion

3. DuPont Coatings & Color Technologies Group Wilmington, DE Coatings Sales: $3.8 billion

4. The Valspar Corp. Minneapolis Coatings Sales: $2.99 billion

5. RPM International Inc. Medina, OH Coatings Sales: $2.3 billion

6. Behr Process Corp. Santa Ana, CA 714/545.7101 www.behr.com CEO/President: Jeff Filley Coatings Sales: Approx. $1.69 billion Masco’s Decorative Architectural Products segment includes Behr Process Corp. and Masterchem Industries, LLC. A leader in the DIY market with The Home Depot, Behr also provides Behr Premium Select paint for professional application through Masco Contractor Services. Masterchem Industries sells under the brand names of Kilz®, Casual Colors®, Expressions®, Hammerite® and others. These brands are sold through big-box stores, national retailers, paint and hardware stores and distributors. Parent Company: Masco Corp. Source: Masco Corp. SEC filing

7. Comex Group

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Mexico City www.thecomexgroup.com CEO: Marcos Achar COO, Mexico Div.: Leon Cohen Coatings Sales: $1.36 billion Comex Group was formed with the consolidation of Comex, Color Wheel, Frazee, General Paint, Kwal, Parker and Duckback. In addition to architectural paints, Comex manufactures industrial coatings, roof coatings, wood-care products and aerosols. Source: Company contact Notes: In 2010, the company divested Ferreterias Calzada and dissolved its joint venture with Akzo Nobel for automotive refinishes.

8. Ennis Paint Inc. Ennis, TX 972/875.7272 www.ennispaint.com Chairman: W. Bryce Anderson Coatings Sales: $387 million Ennis Paint Inc. continues a long history of pavement markings that date back to the 1960s. Ennis Paint is a world leader in both traffic paint and thermoplastics. Source: Company contact

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9. Kelly-Moore Paint Co., Inc. San Carlos, CA 800/874.4436 www.kellymoore.com President/CEO: Steve DeVoe Coatings Sales: $245 million Headquartered in San Carlos, CA, Kelly-Moore is one of the largest employee-owned paint companies in the United States. A leader and innovator of waterborne coating technology, Kelly-Moore was the first major paint manufacturer to offer recycled paints. Kelly-Moore operates 163 company-owned stores in eight states: Arkansas, California, Idaho, Nevada, Oklahoma, Oregon, Texas and Washington. The company is looking to add a number of additional neighborhood locations in 2011. Source: Company contact Notes: In 2010, Kelly-Moore continued to work closely with independent paint retailers by increasing its dealer network to over 150 stores nationwide. The company also enjoyed continued success in distributing its coatings overseas, where the demand is high for quality, American-made products.

10. TIGER Drylac U.S.A., Inc. Reading, PA 800/243.8148 www.tiger-coatings.us CEO: Larry McNeely Coatings Sales: $235 million TIGER is ranked the fifth-largest powder manufacturer in the world

with sales of over $235 million and more than 1,000 employees. It offers the largest selection of top-of-the-line powder coatings in every type of chemistry, serving among others the architectural, automotive, lighting and furniture industries. The U.S. operations were established in 1984. Today, the company ships from six strategic distribution centers. The company’s North American production network includes three facilities in the United States, in California, Illinois and Pennsylvania. Source: Company contact

11. Cloverdale Paint Inc. Surrey B.C., Canada 604/569.6261 www.cloverdalepaint.com CEO: C.A. (Al) Mordy Rodda Paint Co. 800/242.3713 Portland, OR www.roddapaint.com COO: Bill Boone Coatings Sales: $221 million (combined) Cloverdale Paint Inc. and its subsidiaries, Rodda Paint Co., Fargo Paint & Chemicals Inc., and Guertin Coatings, Sealants & Polymers Ltd., operate through 109 corporate-owned locations covering western Canada as well as Washington, Oregon, Idaho, Montana and Alaska. The companies manufacture architectural paint, and industrial and marine coatings along with certain powder coatings, specialty resins and sealant products. Combined markets include sales to a wide

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variety of professional, commercial, residential, industrial, marine, private-label and DIY customers as well as a network supporting Cloverdale Paint and Rodda Paint independent dealers throughout the Pacific Northwest region. Source: Company contact, company Web site

12. Nippon Paint U.S. Subsidiaries Coatings Sales: $190 million (combined) NB Coatings Inc. Lansing, IL 708/474.7000 www.nbcoatings.com CEO: Hidefomi Morita A subsidiary of Nippon Paint Co., NB Coatings is the leading supplier of liquid coatings for plastic automotive parts in North America. It provides a complete line of custom coatings for fascia, exterior trim, interior trim and lens applications. NPA Coatings Inc. Cleveland 216/651.5900 President: Hidefomi Morita NPA Coatings manufactures and sells powder coatings, automotivebody coatings, pretreatment chemicals and transit film to customers in the general industrial and automotive markets. Source: Company contact

13. Whitford Corp. Elverson, PA 610/286.3500 www.whitfordww.com President: David P. Willis, Jr. Coatings Sales: Over $160 million Founded in 1969, Whitford Corp. has dedicated itself to nonstick coatings for the industrial and consumer markets, later expanding to rubber, textiles, rope and cordage, and other markets. Whitford’s first international venture took place in 1971 with the opening of Whitford Plastics Ltd. in the north of England. Current products include: Xylan®, Xylac®, Dykor ®, Xylar ®, Ultralon®, Excalibur ®, Eterna®, HALO®, Eclipse®, QuanTanium®, Quantum2®, Fusion®, PFA+ and others. Whitford has global manufacturing facilities, including sites in Brazil, Italy, the UK, India, China, Singapore, and Elverson, PA. With the acquisition of Polymeric Systems Inc. in mid2004, its portfolio expanded to include a wide variety of adhesive products sold throughout the world to retail, consumer and industrial markets. Source: Company Web site, company contact Notes: In January 2011, Whitford purchased HP Polymers, a leading Canadian manufacturer of a variety of polymer resins. In April 2011, the company opened its ninth factory in Bangalore, India. Manufacturing at the site will concentrate primarily on coatings for consumer products, along with a few specialized industrial applications.

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in Low and VOC free colorant technology for more than 15 years. Our continuous investment in colorant research and development keeps our customers competitive with technical performance requirements and up-to-date with ever-changing legislative actions. European standards for sustainable technology are rapidly becoming the example upon which US environmental regulations are being modeled. CPS Color’s global strength and knowledge of the tinting process from start to finish, ensures that our comprehensive product portfolio, including colorants, equipment, software and support, is the best choice for paint manufacturers. CPS Color specializes in colorant systems ranging from the latest in Zero and Low VOC decorative options to high strength industrial product systems. Our color experts make converting colorant technologies seamless and worry-free; navigating customers through every step of the process. When combined with our state-of-the-art dispensing equipment you are assured the best possible compatibility and overall system performance.

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14. Vogel Paint, Inc. Orange City, IA 712/737.8880 www.vogelpaint.com President/CEO: Drew F. Vogel Coatings Sales: $135 million Vogel Paints was established in 1926 as a manufacturer of barn paints and creamery maintenance enamels. It entered the liquid industrial coatings market in the 1950s and began to build a fleet of company stores selling architectural paints and heavy-duty maintenance coatings in the 1970s. The company formed the Peridium Powder Coatings division in 1998 and built a new powder coatings production facility in 2003. Today, the company operates over 70 company stores and seven manufacturing plants and distribution centers in 13 states. Source: Company contact Notes: In May 2011, Diamond Vogel announced a partnership with Sciessent, creator of the silver-based antimicrobial brand Agion®, to offer the Peridium® Powder Coatings line. The new Peridium line brings the quality and durability that industrial customers have found synonymous with the Vogel name with the added benefit of Agion antimicrobial product protection.

16. Ace Hardware Corp. Oakbrook, IL 630/990.6600 www.acehardware.com CEO/President: Ray A. Griffith Chairman of the Board: Dave Ziegler

Coatings Sales: $125 million Ace Hardware is the largest retailer-owned hardware cooperative in the industry. Ace manufactures a full assortment of paints, stains, primers and light-industrial products with its primary business centered on the Ace ROYAL™ brand. All Ace Paint-branded products are produced in one of two facilities owned and operated by the Ace Paint division. Both facilities are located in the south suburbs of Chicago, IL, and are ISO 9001 (quality management) and ISO 14001 (environmental management) certified. In April 2010, Ace Paint, a division of Ace Hardware Corp., announced the launch of Royal Finest™, a premium, low-VOC, acrylic latex paint with Scotchgard Protector. The new paint offers consumers the opportunity to be environmentally responsible, while still providing ultimate stain resistance. Source: Company contact, press release

17. Tnemec Co., Inc. Kansas City, MO 800/863.6321 www.tnemec.com CEO/President: Peter Cortelyou Coating Sales: $115.8 million Tnemec Co. manufactures more than 100 architectural and industrial coatings, from premium epoxies and polyurethanes to specialized fluoropolymer products, formulated specifically for extreme durability, enduring performance and enhanced aesthetics. Tnemec is a leading supplier of interior and exterior coatings for water storage tanks. Tnemec’s StrataShield brand consists of resinous floor and wall coatings. The company’s Chemprobe subsidiary offers water-repellant and stain products for concrete, masonry and wood. Subsidary: Chemprobe Coating Systems Source: Company contact

18. Spraylat Corp. Pelham, NY 914/738.1600 www.spraylat.com CEO: Michael Borner President: Raymond T. Chlodney Coatings Sales: $115 million Spraylat Corp. is a supplier to the product-finishing market, offering both decorative and functional coatings. Spraylat offers powder coatings for a wide variety of applications, including architectural powder coatings that exceed AAMA specifications. It offers high-technology coatings, including electrically conductive coatings for EMI/RFI shielding and Polymer Thick Film (PTF) inks for membrane switches and printed antennas. Spraylat’s Liquid Business Unit provides high-performance coatings for heavy equipment, automotive, sign coatings and specialty OEM applications, as well as solutions and coatings for the manufacture of mirrors. Spraylat’s global operations include locations in North America, Europe and Asia. Subsidiaries: One Shot LLC, Spraylat GmbH (Germany), Spraylat Coatings (Shanghai) Ltd., Spraylat Boya Ltd. (Turkey) Source: Company contact

19. Quest Specialty Chemicals, Inc. Menomonee Falls, WI 800/966.7580 www.questsc.com CEO: Fred Quinn COO: Gerry Loftus Coatings Sales: $112 million Quest Specialty Chemicals is funded through private equity by the Audax Group, located in Boston, and Moelis Capital Partners, located

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in New York. The company acquires and builds specialty chemical companies in the coatings arena. It is organized into two principal divisions focusing on transportation, industrial and construction coatings. The Specialty Coatings division consists of the following subsidiaries: Matrix System Automotive Finishes LLC; Raabe Co. LLC; and Zolatone Automotive, Industrial, and Marine. United Coatings Manufacturing Co. and HydroStop LLC form the Quest Construction Products division. Quest Construction Products offers a full line of protective coatings for a wide range of architectural, industrial and roofing applications. Matrix System Automotive Finishes is an independent manufacturer and distributor of aftermarket automotive refinish paint products, marketing paints, primers, clearcoats, hardeners and solvents. Raabe Co. manufactures custom-matched branded touchup paint and provides private-label aerosol and liquid paint filling services. Source: Company contact, company Web site

20. Yenkin-Majestic Paint Corp. Columbus, Ohio 614/253.8511 www.majicpaints.com www.yenkin-majestic.com www.opcpolymers.com President: Jonathan M. Petuchowski COO: Andrew O. Smith Coatings Sales: $105 million Yenkin-Majestic’s full line of architectural paints includes interior and exterior products and a variety of specialties, including a

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complete farm program, low-VOC oil-based floor paints and a unique acrylic enamel line (Diamond Hard). Its industrial division manufactures waterborne and solventborne products, including urethanes, epoxies and polyesters. Its OPC Polymers operations serve the United States, Canada and other markets, with expansion in 2010 by the acquisition of SI Group-Canada Ltd. Product categories include alkyds, oil-modified urethanes, monomer-modified combinations, high solids, water reducibles, alkyd dispersions, epoxy esters and VOC-compliant vehicles. Source: Company contact

21. ELANTAS PDG Inc. St. Louis, MO 314/621.5700 www.elantas.com CEO/President: Susan W. Graham Coatings Sales: $100 million ELANTAS PDG Inc. is a premier supplier of specialty polymers for the electrical and electronic industries. The key products of ELANTAS PDG include magnet wire enamel, insulating varnishes and encapsulating resins. It also produces tubing and sleeving varnishes, pultrusion resins, laminating resins, adhesives, and conformal coatings. Parent Company: ALTANA, AG, of Germany Source: Company Web site, press releases, company contact

22. California Products Corp. Andover, MA 978/623.9980 www.californiapaints.com CEO/President: Peter Longo Coatings Sales: $80 million California Paints manufactures coatings for architectural, consumers and contractors under the brand names California Paints, Storm Stain and California Performance Coatings. California Products produces interior and exterior architectural paints. Source: Company contact, Web site Notes: In August 2009, California Products Corp. acquired the customer base and certain assets of Progress Paint Manufacturing Co. The acquisition included certain Progress Paint brands and product lines including Gray Seal®, Fixall®, Duralux® Marine and other associated lines.

23. Vista Paints Manufacturer of organo modified & reactive silicones. SILTECH CORPORATION 225 Wicksteed Avenue, Toronto, Ontario, Canada, M4H 1G5 Tel: (416) 424-4567 Fax: (416) 424-3158 www.siltechcorp.com

Fullerton, CA 714/680.3800 www.vistapaint.com CEO/President: Eddie Fischer Coatings Sales: $75 - 100 million Vista Paints, founded in 1960, is a manufacturer of high-quality coatings for the architectural and industrial-maintenance markets for sale through company-owned stores throughout California and Nevada. Its customers include the professional painter and the DIY consumer. The stores supply wallpaper, window coverings and related painting supplies in addition to paint. Source: Company contact

24. True Value Co. Chicago 773/695.5000 www.truevaluecompany.com President/CEO: Lyle G. Heidemann Coatings Sales: Approx. $70 million True Value Co. manufactures exclusive paint brands for its retail identities as well as private-label brands for third-party accounts.

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Paint is manufactured under the EasyCare and Weatherall brands in Cary, IL, and distributed nationally to its core hardware stores. True Value Co. is one of the world’s largest retailer-owned hardware cooperatives with sales of $1.8 billion in 2010. The True Value cooperative includes approximately 4,700 independent retailer locations worldwide operating under the store identities of True Value, Grand Rental Station, Taylor Rental, Party Central, Home & Garden Showplace and Induserve Supply. Source: 2010 Annual Report, company contact

25. Gemini Industries El Reno, OK 405/262.5710 www.gemini-coatings.com CEO/President: David Warren Coatings Sales: $40 million Founded in 1964, Gemini Industries is an employee-owned company that manufactures and distributes an extensive line of coatings, aerosol products and touchup materials for the architectural woodfinishing market. A sophisticated line of high-performance coatings for cabinet makers, furniture finishers and refinishes represents 50 percent of sales. It also manufactures a line of EPA-registered wood preservatives and related products for use on exterior decks, siding and fences. Gemini has five plants and distribution facilities that provide nationwide service. Parent Company: Gemini Industries Source: Company contact

United Gilsonite Laboratories Dunmore, PA 570/344.1202 www.ugl.com CEO/President: Thomas White Coatings Sales: $40 million United Gilsonite Laboratories (UGL) manufactures over 80 paintspecialty and home-maintenance products that are sold nationally and internationally at hardware stores, home centers, paint stores and lumberyards. Its main brands are Zar and Drylok. UGL exports products to nearly 80 countries. Source: Company contact

Unreported/Unranked: Benjamin Moore & Co. Montvale, NJ 201/573.9600 www.benjaminmoore.com President/CEO: Denis Abrams Coatings Sales: Not reported Benjamin Moore & Co. is primarily a North American paint company. Its products are sold nationally through independent paint stores. It specializes in architectural coatings with some industrial maintenance coatings. The company has a small amount of sales overseas. Parent Company: Berkshire Hathaway Inc. Source: Company Web site, company contact

Dunn-Edwards Corporation Los Angeles 323/771.3330 www.dunnedwards.com CEO: Kenneth N. Edwards President/COO: Karl Altergott Coatings Sales: Not reported Dunn-Edwards operates 109 stores in five western states: California,

Arizona, New Mexico, Nevada and Texas. It is a manufacturer and supplier of architectural and industrial coatings, providing a complete line of paints and professional painting supplies. The company caters to architects, designers, painting contractors, homebuilders and property managers in the Southwest. It also serves do-it-yourselfers, although professionals account for a majority of sales. Source: Company contact, company Web site, press releases Notes: In December of 2010, Dunn-Edwards introduced two new lines of paint products, SPARTASHIELD ® exterior 100-percent acrylic paints and SPARTAWALL™ interior acrylic paints. In April of 2011, Dunn-Edwards launched ARISTOWALL™, a line of premium interior enamel finishes formulated with advanced water/oil hybrid technology.

Honorable Mention: Farrell-Calhoun Inc. Memphis, TN 90l/526.2211 www.farrellcalhoun.com President: John A. Ward Jr. VP Sales/Marketing: Anthony Ward Coatings Sales: $28.4 million Farrell-Calhoun manufactures architectural and industrialmaintenance coatings. The company has distribution throughout the mid-south and southeast through 30 company-owned stores and a network of 100 dealers. Source: Company contact

The Muralo Co. Inc. Bayonne, NJ 201/437.0770 www.muralo.com President: James S. Norton Coatings Sales: $18 million Muralo manufactures a broad line of architectural coatings sold through independent paint stores. With manufacturing located across the United States, Muralo can supply its customers nationally. Muralo also offers Spackle® spackling compound and brush, patch and repair products. Subsidiaries: Elder and Jenks Inc., Synkoloid, and Graham Paint and Varnish Co. Source: Company contact

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PA I N T & C O A T I N G S I N D U S T R Y

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Enhanced Dry-Film Through Controlled

B

iocides are necessary to p prevent reve re vent nt the the microbial deterioration of many industrial coatings. The two main applications of biocides are (a) to prevent spoilage of the wet-state product during storage and transport (incan protection), and (b) to ensure long-term performance of the coating (dry-film protection).1 Upon drying, both water- and solvent-based coatings are susceptible to colonization by fungi and/or algae. The growth of microorganisms on dry film not only affects the appearance of the coating (discoloration), but it may also compromise its performance (biodeterioration). Fungi can penetrate coatings, resulting in cracking, blistering and loss of adhesion, leading to decay or corrosion of the underlying substrate. Algae colonies, which seem to grow more rapidly on porous substrates such as stucco, cement and bricks, have the ability to occlude water. The freezing and thawing of this entrapped water may induce cracking or increase the permeation properties of the coating, leading to failure. The presence of water may also encourage colonization by other microorganisms that, in turn, may cause biodeterioration.2 The type of microorganism that can colonize the coating will depend on several factors, including moisture content of the surface, presence of nutrients, substrate and coating composition.3 In order to be most effective, the biocide needs to be present at the coating interface. This makes it susceptible to water leaching. Controlling the release of the biocide through encapsulation could ensure that a minimum concentration of biocide is always maintained at the surface interface, extending the shelf life of the coating. Additionally, this controlled release could reduce the amount of biocide that is released to the environment over a period of time. This paper describes the controlled release of IPBC (3-iodo-2-propynyl butylcarbamate) through encapsula-

FIGURE 1 | Cumulative IPBC leaching out of films.

tion tion. Long-term protection of the surface is enabled through the adsorption interaction between the biocide and the carrier.4,5 This renders the biocide more resistant to leaching. Encapsulated IPBC was released more slowly than nonencapsulated, as measured by analytical and microbiological methods. The encapsulated biocide was also more resistant to environmental degradation from UV/heat. Furthermore, outdoor exposure tests of paints containing encapsulated IPBC showed enhanced dry-film protection.

Experimental Paint Film Sample Preparation Encapsulated and non-encapsulated IPBC were added at various levels to paint samples. Drawdowns were prepared by casting 3-mil films onto drawdown paperboard (Lanetta) and allowed to dry at room temperature for at least 24 h.

IPBC Measurements IPBC Present in Leachate Water Paint samples were prepared as described above containing 10,000 ppm of IPBC. Paint films were suspended in 100 mL water with constant stirring. The leachate water was collected at different time intervals and analyzed by GC UV-Vis spectroscopy for IPBC content. The concentration of IPBC was determined using a standard IPBC curve at maximum absorbance of 224-228 nm. Quantification of IPBC in Paint Films by XRF Paint samples prepared as described above containing 2,000 ppm of IPBC were leached for various time intervals at a leach rate of 1 liter per hour. Samples were dried for at least 24 h. The PANalytical Epsilon 5 X-Ray Fluorescence (XRF) instrument was used to analyze the samples for iodine content.6 A standard IPBC curve was developed with different concentrations of IPBC and was linear up to 4,000 ppm of IPBC. The linear correlation was independent of the paint formulation used to make the film. Base lines of each paint film were obtained before and after leaching.

14 13

IPBC

% IPBC

12 11

Fungitrol® 940CR

10 9 8 7

1

3

15

48

Hours

Delta Y Measurements Paint samples were prepared as described above containing 1,000 ppm of IPBC. Samples were placed in the QUV unit under UVB bulbs for 24 h. The YI (yellowness index) was measured with a spectrophotomer (CM2500d from Konica Minolta) within 1 h after taking the films from the QUV unit (ASTM E 313 - 10 Standard Practice for Calculating Yellowness and Whiteness Indices from Instrumentally Measured Color Coordinates). The Delta Y was determined by subtracting the YI of the biocide-treated sample minus the untreated control sample after QUV exposure.

By Raman Premachandran, Sr. Scientist II, and Karen Winkowski, Sr. Technical Director, Performance Chemicals & Industrial Biocides | ISP, Wayne, NJ 36

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Coating Performance -Release IPBC Accelerated Fungal Testing ASTM D 5590 (Determining the Resistance of Paint Films and Related Coatings to Fungal Defacement by Accelerated Four-Week Agar Plate) was used to measure efficacy of the various biocide treatments on the paint films. Samples were prepared as described above except that 500 ppm of IPBC was added to the paint samples. Paint samples were leached as described above and inoculated with a mixed fungal suspension consisting of Aspergillus niger (ATCC 6275) and Penicillium funiculosum (ATCC 11797), 107 spores/mL final concentration. The plates were then incubated for 28 days at 28 ºC and 85% RH. Fungal growth was rated on the surface of the painted sample on a scale from 0-4, where “0” represents no growth; 1 represents traces of growth (< 10%); 2 represents light growth (10-30%); 3 represents moderate growth (30-60%) and 4 represents heavy growth (60% to complete coverage). Outdoor Test Fence Exposure Paint samples were prepared containing 3,000 ppm of IPBC (encapsulated and non-encapsulated). Western Red Cedar was used as a substrate. Every panel was brush coated with one coat of primer on the smooth veneer side and also back coated with one coat of aluminum paint. The panel was divided into three equal 1-foot sections. The center served as a control and received two coats of the paint with no fungicide. The left and the right sides received two topcoats of biocide-treated paint. After drying, the panels were exposed facing North at a 90º angle.

measured after 28 days of incubation. incubation As shown in Table 1, the encapsulated biocide (IPBC CR) provided longerlasting protection to the surface of the sample (0 rating) after extensive leaching. Tests were also conducted outdoors. Wood panels containing encapsulated vs. non-encapsulated IPBC were exposed in the test fence. A quick-fail acrylic exterior paint was used in these studies. After 18 months exposure, samples were evaluated for the degree of defacement on the paint surface. As shown in Figure 3, the sample containing the encapsulated biocide showed the least surface defacement. Additional experiments were conducted to demonstrate that the encapsulated IPBC shows reduced yellowing when exposed to UV light. Paint samples containing the different biocides at 1,000 ppm were exposed to UV radiation (B-bulbs, 24 h). As shown in Figure 4, the encapsulated biocide was less susceptible to yellowing after UV/ heat exposure in the two different paints tested.

FIGURE 2 | IPBC on film surface after 24 h leaching. 65 IPBC on the Film Surface

Efficacy Studies

Results and Discussion The controlled release of IPBC from paint films was investigated in different ways. The films were placed in water and the leachate was collected at various time intervals. The amount of IPBC that leached out was measured by UV spectroscopy. Figure 1 shows the cumulative IPBC content in the leachate. Encapsulating the IPBC (IPBC CR) resulted in a decreased amount of IPBC leaching out of the film. In order to measure the amount of IPBC remaining on the surface of the coating, a nondestructive X-Ray fluorescence (XFR) methodology was developed. As shown in Figure 2, the amount of IPBC remaining in the film was higher for the encapsulated IPBC. The amount of IPBC released also depended on the intrinsic properties and composition of the paint. In this example, the glossy paint showed higher retention levels of the IPBC than the flat paint. Microbiological tests were additionally used to demonstrate the controlled release of the encapsulated IPBC. Surface protection assays were conducted according to ASTM Method D 5590. In this four-week accelerated study, the amount of fungal growth on the sample was

60 55 50

IPBC Fungitrol 940CR

45 40 35 30

Flat

Gloss

FIGURE 3 | Test fence exposures (quick-fail acrylic exterior – 18-month exposure).

Fungitrol 940CR IPBC Control

0

20

40

60

80

100

% Surface Defacement

TABLE 1 | Growth ratings on the surface of the sample after 28 days. Aqueous Dispersion/Control Control (no biocide) IPBC-CR IPBC

0h 4 0 0

Leaching 48 h 72 h 4 0 2

96 h

4 0 4

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4 0 4

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Enhanced Dry-Film Coating Performance Through Controlled-Release IPBC

degradation processes (such as UV/heat degradation), further enhancing dry film protection. IPBC CR is currently available from ISP as a 40% IPBC dispersion under the trade name Fungitrol® 940CR. 䡲

FIGURE 4 | Protection against yellowing. 12

Delta Y

10

References

8 6

Fungitrol 940CR IPBC

4 2

1

2

3

0 Styrene acrylic

Acrylic 4

Conclusions The controlled release of IPBC through microencapsulation into an inorganic carrier was demonstrated by analytical and microbiological assays. The controlled release mechanisms maintain a minimum biocide concentration in the coating interface over an extended period of time, preventing fungal growth. This results in a longer coating shelf life given the same initial biocide concentration. Alternatively, lower biocide levels could be used to obtain a similar shelf life. The inorganic carrier provides the molecule additional protection against environmental

5

6

Woods, W.B. Industrial Biocides for Use in Coatings, Australian Coatings Journal 2000, No.6, 6. Wright, I.C. The Deterioration of Paint Films by Algae and Lichens, Biodeterioration, VI, 1986, 637. Bussjaeger, S.; Daisey, G.; Simmons, R.; Spindel, S,; and Williams, S. Mildew and Mildew Control for Wood Surfaces, Journal Of Coatings Technology 1999, 71, No.890, 67. Alkan,M.; Karada¸ M.; Mehmet Do˘gan, S. Özkan Demirba, S. Adsorption of CTAB onto perlite samples from aqueous solutions, Journal of Colloid and Interface Science 2005, 291, 309–318 Malina, R; Ligia, T; Maria, C; Ana B, Adrianac, R; Corina, B; Adrian, C; Maria, Z. Sol-Gel Materials with Pesticide Delivery Properties, Journal of Environmental Protection 2010, VOl 1, No 3. http://www.panalytical.com; Refer to Articles on XRF by Pananlytical for metal and iodine determination.

This paper was presented at the 38th Annual Waterborne Symposium, February 2011, in New Orleans.

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®

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New Vinyl Acetate Takes Semigloss

E

nvironmental regulations and market forces are pushing for lower VOC levels in all architectural coatings. In particular, allowable VOC limits for architectural semiglosses are dropping below 50 g/L in some regions. This article reviews current environmental regulations, as well as various market and industry organizations that are pushing semigloss VOC limits ever lower. In addition, an experimental design used to select the best latex for <50 g/L semigloss, along with some design-driven formulation optimization, is discussed. The overall objectives are to 1) identify the best VAE developmental latex compositions and formulation ingredients; 2) benchmark a competitive VAE; and 3) answer the conceptual question as to whether 50 g/L semiglosses are viable. Forbo has developed new vinyl acetate ethylene latexes for the coatings market. One of the newest products is ELVACE® 750, a high solids, non-APEO, ultralow-VOC, no formaldehyde-added vinyl acetate latex for flat and semigloss coatings.

Environmental and Market Forces What are the VOC regulations for semigloss coatings for architectural applications? How prevalent is 50 g/L as a requirement, and is it regulation or market driven? Historically, the primary VOC driver has been the regulatory climate. The South Coast Air Quality Management District (SCAQMD) leads the country in lowVOC regulations. The SCAQMD includes the Los Angeles basin in southern California. Their current regulation FIGURE 1 | Stormer viscosity by surfactant (average defoamer).

Paint Project

94

The purpose of this paint project was to use a factorial experimental design to identify the best overall latex composition, surfactant type and defoamer needed to make a <50 g/L semigloss with acceptable performance.

92

Formulation

96

Stormer

for architectural semigloss is less than 50 g/L. While the rest of California, and eventually the rest of the country, typically follow SCAQMD’s lead, current regulations are somewhat higher. The California Air Resources Board (CARB) is at 150 g/L for semigloss, with a proposal to reduce VOCs to 100 g/L. The Ozone Transport Commission (OTC), a consortium of northeastern/mid-Atlantic states, follows CARB, and is currently at 150 g/L. The EPA level for semigloss (the national level) is 380 g/L. EPA allows the various regions, like OTC, CARB and SCAQMD to set their own, more-stringent requirements as local pollution and air-quality issues dictate. The overall regulatory conditions suggest that for the time being, 100 g/L, or even 150 g/L is perfectly acceptable for semigloss coatings, as long as you’re not selling paint in SCAQMD’s district. However, there are other forces at work to reduce VOCs. The coatings consumer is environmentally aware and understands terms like “VOC” and “low odor.” There are more organizations that certify “green” coatings. Two of the most notable groups with low-VOC requirements are Master Painter’s Institute (MPI) and GreenSeal. For their GPS-2 and more stringent certifications, MPI requires 50 g/L for semigloss coatings, along with comprehensive performance requirements. GreenSeal GS-11 certifies 100 g/L with some performance requirements. GreenSeal also specifies non-APEO (alkyl phenol ethoxylate). This means the stabilization of the latex and the paint additive package must be non-APEO. So, the requirement for 50 g/L or less in architectural semigloss is driven both by the regulatory climate as well as the market and organizations that certify green coatings.

90 88 86 84 Anionic

Exp-3 Exp-2 Exp-1

B: Surfactant

Nonionic

Comp-4

A: Latex

The screening formulation was at a pigment volume concentration (PVC) level of 29%, 34% volume solids. It had no APEO surfactants, a 95% VOC-free bio-coalescent (Loxanol EFC-200 from Cognis/BASF), a small amount of propylene glycol for wet edge, some hydroxyl ethyl cellulose (Natrosol 250 MBR) and attapulgite clay (Attagel 50) as co-thickeners, and a VOC/APEO-free polyether rheology modifier (NMS-450 from Aqualon/Ashland). The pigment extender was a fine-particle-size clay, Polygloss 90. The prime pigment was an easy-dispersing, general-purpose titanium dioxide from DuPont, TiPure R706.

By Rick Caldwell, Research Associate and Project Leader, Coatings | Forbo Bonding Systems, Synthetic Polymers Group, Morrisville, NC 40

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Ethylene Latex Coatings Green Latex The four latexes included a competitive vinyl acetate ethylene (VAE) latex, as well as three experimental VAEs. The experimental VAEs were all non-APEO, with no added VOCs or formaldehyde, low free vinyl acetate monomer (<0.05%), and ultralow-VOC capable. Additionally, all were 65% solids by weight. This provides the coatings manufacturer with a sustainability advantage: higher solids means fewer truckload shipments of latex over any given time to provide the same amount of latex solids. The three experimental latexes were designated EXP-1, EXP-2 and EXP-3. EXP-2 is the lab prototype for ELVACE 750. The competitive VAE was 55% solids by weight and contained APEO surfactants. It is a well-established, “industry standard” coatings latex. Surfactants Two surfactants were tested: a nonionic, WA120 from Rhodia; and an anionic, Strodex PK-ZeroVOC from Aqualon/Ashland. Both surfactants were non-APEO. A surfactant level of 3 solid lb/100 gal was used. The WA-120 nonionic was 100% solids (active), with an HLB of 10-11. The Strodex PK-ZeroVOC anionic was a phosphate ester at 42% solids by weight. For the rest of this article, the surfactants will be identified as nonionic and anionic. Defoamers Two defoamers were tested at a 3 lb/100 gal level, added in the letdown. Both were 100% active and silica-based. Extensive supplier research indicated that silicabased defoamers versus their mineral oil, non-silica counterparts give better gloss and less haze in semigloss systems.

They also provide better deaerating and defoaming efficiency. The first defoamer, Dehydran 2620 from Cognis/BASF, was a polymeric polysiloxane type. The second, Foamex 858 from Evonik, was an emulsion of a polyether polysiloxane copolymer. For the rest of the article, they are identified as Defoamer A and Defoamer B, respectively.

remove expensive thickeners in the formulation. Note that while the viscosities were in some cases significantly higher, they were stable viscosities (as determined by oven stability testing). Figure 1 shows the latex and surfactant viscosity advantages. Defoamer selection, which has a significant but small impact, was considered as “average” for the two defoamers.

Test Methods

Gloss @ 60°

Several standard semigloss test methods were performed in conjunction with this study. Five main results are reviewed in this paper. They are 1) Stormer viscosity; 2) gloss @ 60°; 3) block resistance; 4) lowtemperature touchup; and 5) cleansability. The results are considered in terms of the statistical design. The statistically significant factors – latex, surfactant and defoamer selection – for each response are discussed. Interactions – where two or more factors combine for an unexpected result – are highlighted. Interactions are widely considered the “gold standard” of statistical design of experiments.

All three factors are significant in this response: latex, surfactant and defoamer. EXP-2 and EXP-3, along with nonionic surfactant and Defoamer B gave generally higher overnight paint viscosities. Higher Stormer viscosities are deemed to be favorable, allowing the formulator to

The results shown in Figure 2 present a clear interaction between latex selection and surfactant – the two critical factors. An interaction is where one or more factors diverge from a standard profile. In this case, the competitive latex showed an unexpectedly low gloss with the anionic surfactant. The three developmental latexes, including the ELVACE 750 prototype, showed little difference in the response with either anionic or nonionic surfactant. The area of interaction is circled in red. EXP-2 and EXP-3 actually showed slightly better gloss development with the anionic surfactant. However, gloss development with those two latexes was very good regardless of nonionic or anionic surfactant selection. Figure 3 shows a bar graph of the interaction featured in Figure 2. The good gloss development of the EXP-2 and EXP-3 experimental latexes, which includes the prototype, shows clearly in the graph.

FIGURE 2 | Interaction graph showing gloss @ 60°.

FIGURE 3 | Bar graph showing gloss @ 60°.

Stormer Viscosity

55

B: Surfactant 55

50

50

45 Design-Expert® Software Factor Coding: Actual Gloss @ 60º

40

• Design Points X1 = A: Latex X2 = B: Surfactant

35 30 Comp-4

Gloss @ 60º

A general factorial design was used to screen for the optimum latex, surfactant and defoamer. Essentially there were three factors: 1) latex selection; 2) surfactant type; and 3) defoamer product. There were four different latexes (levels), two surfactants and two defoamers.

Gloss @ 60º

Experimental Design

45 40 35 30 Anionic

Actual Factor C: Defoamer = Defoamer B

A: Latex Exp-1

■ B1 Nonionic ▲ B2 Anionic

Exp-2

B: Surfactant

Nonionic

Exp-3 Exp-2 Exp-1 Comp-4 A: Latex

Exp-3

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New Vinyl Acetate Ethylene Latex Takes Semigloss Coatings Green

FIGURE 4 | Interaction graph showing composite block resistance.

80 60

Low-Temp Touchup

140 120 100 80 60 40 20

Block, Combined

Block, Combined

Design-Expert® Software Factor Coding: Actual Block, Combined

• Design Points

100

X1 = A: Latex X2 = B: Surfactant Actual Factor C: Defoamer = Defoamer B ■ B1 Nonionic ▲ B2 Anionic

40

Exp-3 Exp-2 Exp-1 B: Surfactant Nonionic Comp-4 A: Latex Anionic

20

A: Latex

Comp-4

Exp-1

Exp-2

Block resistance measures a dry film’s propensity to stick to itself, and was run according to ASTM D 4946 (scale of 0-10; 10 = no blocking; 0 = complete failure). One-inch squares were blocked face-to-face and face-to-blank under a 1000 g weight using different dry and dwell conditions. Table 1 illustrates the 16 readings that are routinely run. The data presented in this paper is the composite of all of the ratings for each of the 16 panels tested for each individual sample. A perfect block resistance rating – 10s on every sample – would have a composite rating of 160. Figure 4 shows the results and an interaction. The two developmental latexes, EXP-2 and EXP-3, had excellent block resistance – typically 7-9 ratings across the spectrum of test conditions – with the nonionic surfactant. The composite readings are lower with the anionic surfactant. The competitive latex and EXP-1 both showed poor block resistance, regardless of surfactant. The interaction area is circled.

TABLE 1 | Block resistance test panels, rated per ASTM D 4946. Overnight Dry

Room Temperature Block

4-h dwell

Face to-face Fack-to-blank

16-h dwell

Face to-face Fack-to-blank

Oven @ 50 ºC Block

4-h dwell

Face to-face Fack-to-blank

16-h dwell

Face to-face

4-h dwell

Face to-face

Fack-to-blank

One Week Dry

Room Temperature Block

Fack-to-blank 16-h dwell

Face to-face Fack-to-blank

Oven @ 50 ºC Block

4-h dwell

Face to-face Fack-to-blank

16-h dwell

Face to-face Fack-to-blank

Total:

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1.20 1.00 0.80 0.60 0.40 0.20 Anionic

Exp-3 Exp-2 Exp-1 Nonionic Comp-4 B: Surfactant A: Latex

Exp-3

Block Resistance

42

FIGURE 6 | Low-temperature touchup, DE.

B: Surfactant

140 120

FIGURE 5 | Bar graph showing composite block resistance.

JULY 2011 | W W W . P C I M A G . C O M

16 Panels

Figure 5 shows a bar graph illustration of the interaction graph. The excellent block resistance with the two developmental latexes, EXP-2 and EXP-3, in conjunction with the nonionic surfactant, is clearly visible. Even with the poorer blocking anionic surfactant, the EXP-2 and EXP-3 were the best.

Low-Temperature Film Formation Low-temperature film formation was measured by placing tinted films of each coating in the refrigerator at 36 °F and allowing them to dry for 16 h. Color (L, a, b values) was measured on the room-temperature dried panels, and then the low-temperature dried panels. A BYK/Gardner Color-Guide Sphere color meter was used for this test. Color change results are expressed as ΔE (square root of the sum of the squares of the differences in L, a, and b values). The data shows that EXP-2 (ELVACE 750 prototype) and the competitive latex exhibited the best low-temperature coalescence, particularly with the nonionic surfactant. It should be noted that the established competitive latex is well known for its advantages in low-temperature coalescence. Overall, the anionic surfactant was not as effective in providing low-temperature coalescence as the nonionic surfactant. It is interesting to note, however, that all of the latexes except the EXP-1 variation with anionic surfactant showed ΔEs of markedly less than 1.0. The literature cites, conditionally, that a ΔE of less than 1.0 is not visible to the human eye and hence not significant. Figure 6 illustrates the impact of surfactant and latex selection on low-temperature film formation. Defoamer has a small but statistically significant impact. The figure uses “average” defoamer readings.

Cleansability Cleansability was tested per the method listed in the Master Painters Institute specifications. Five stains – ketchup, mustard, hot coffee, red wine and 325 mesh graphite – were applied to a test film. After a 10 min set, they were rinsed and placed on the scrub machine. A sponge (rather than brush) and a dilute soap/TSP solution were used. The test duration was 1000 cycles. Color readings (L, a, b values) were measured on the initial drawdown and the cleaned stained areas; ΔEs were calculated. The data reported in this study is the composite: the sum of ΔEs for each individual stain.

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New Vinyl Acetate Ethylene Latex Takes Semigloss Coatings Green

Conclusion

FIGURE 7 | Cleansability, composite reading, DE. 30.00

Cleansability

24.00 18.00 12.00 6.00 0.00 Anionic

Exp-3 Exp-2

B: Surfactant

Nonionic

Exp-1 Comp-4

A: Latex

Figure 7 shows a graphical representation of the data. The two significant factors are latex and surfactant selection. As in the previous low-temperature touchup property, the lowest ΔE results are the best. The EXP-2 and EXP-3 VAE latexes provided the best cleansability, regardless of surfactant. The anionic surfactant gave the best cleansability for any given latex.

Optimization This article shows a considerable body of data on four different latexes, two different surfactants and two different defoamers. Another function available in the statistical design software is an “optimization.” Specific requirements can be fed into the program, which will then calculate which combinations of factors come closest to meeting those requirements. The nearness to meeting all the requirements is expressed in a “desirability rating.” A desirability rating of 100% means that particular combination of factors meets 100% of the requirements. The requirements for this particular optimization were simple: • Highest Stormer viscosity; • Highest 60° gloss; • Highest composite block resistance; • Best (lowest ΔE) low-temperature touchup; • Best (lowest ΔE) composite cleansability. The resulting best composition, with an 88.4% desirability rating, was EXP-2 (ELVACE 750 prototype), the nonionic surfactant, and Foamex 828 defoamer. For the other promising latex, EXP-3, the best desirability rating was 80.4%, using the same surfactant (nonionic) and defoamer (Foamex 828). Conversely, the best desirability rating for the competitive latex was 25.6%. Since the competitive latex is an established product in the marketplace, the conclusion is that EXP-2 shows sufficient advantages to warrant scaleup and commercialization. The optimization function is a useful tool, but it is based on the paint samples prepared. For example, it does not indicate whether blends of the two surfactants might lead to synergies in properties like gloss and cleansability, where the anionic showed some advantages. This aspect will be evaluated in future efforts. 44

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Several conclusions can be gained from this work. First, the work affirms that viable, <50 g/L semiglosses can be made using vinyl acetate ethylene latex technology. These semigloss coatings showed excellent gloss, low-temperature film formation, block resistance and cleansability. Second, the overall study shows the usefulness of the factorial experimental design in identifying optimum ingredients – in this case latex, surfactant and defoamer. By including a competitive reference in the study, a comprehensive benchmark on that material is provided. The results show that surfactant selection, especially nonionic versus anionic, is critical to maximizing semigloss performance. On the other hand, defoamer selection is often statistically significant in the various performance areas, but the impact is generally much smaller than the nonionic/anionic surfactant impact. Overall, the results show the importance of carefully selecting surfactants and defoamers for optimum properties. Finally, the EXP-2 latex is an excellent prototype for scaleup and further work, showing a very good balance of properties. The design results show that it is clearly an improvement over existing commercial VAE latex technology. 䡲

Acknowledgements The author would like to acknowledge the management of Forbo Bonding Systems, Synthetic Polymers for allowing this work to be presented. Special thanks to my colleagues at Forbo who supported this project: Russ Frank, Rich Vetterl, Janice Mayer, Tim Tegen and Ashley Hebert.

References 1. MPI Green Performance Standard, http://www.paintinfo. com/GPS/gps.pdf. 2. Detailed Performance Standard, MPI #138, Latex Interior High Performance Velvet-like White & Tints, Section 7.11 cleansability testing, Master Painters Institute, Issued: 3/8/2006. 3. South Coast Air Quality Management District Rule 1113, http://www.aqmd.gov/rules/reg/reg11/r1113.pdf. 4. Sherwin-Williams LEED, Green & VOC Coatings Reference Guide, http://www.sherwin-williams.com/pdf/specifications/SW_LEED_VOC_ReferenceGuide.pdf. 5. PPG Carb Review, http://buyat.ppg.com/ppggreen/certifications-and-regulations/California-Air-Resources-Board. aspx. 6. Green Seal GS-11 Environmental Standard for Paints & Coatings, www.greenseal.org. 7. GreenGuard Indoor Air Quality (IAQ) Standard for Building Materials, Finishes, and Furnishings, www.greenguard.org. 8. Green solvents remain solvents from a VOC perspective but they can bring HS&E benefits, http://www.specialchem4coatings.com/resources/print.aspx?id=13949. 9. Architectural and Industrial Maintenance (AIM) Coatings Volatile Organic Compound (VOC) Emissions Regulatory Update, http://www.paint.org/news/08-02-10-issue05.cfm. 10. CARB Suggested Control Measure for Architectural Coatings, http://www.arb.ca.gov/coatings/arch/ approved_2007_scm.pdf. 11. Ozone Transport Commission, www.otc.org. 12. Paint/Coatings Dictionary. FSCT, 1978.

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New-Generation Three Roll Mills Meet Today’s Challenges

F

or decades, three roll mills have been used in many different industries, from ink, paint and food, to high-tech industries like electronics, energy storage and energy conversion. Everywhere in the coatings industry, where relatively small batches and color changes are often required, three roll mills are one of the best solutions. For example, bases for can and coil coatings are often produced on three roll mills. Also, for heat-sensitive coating systems, like UV-curable coatings, the only solution is often the three roll mill because of its huge cooling surface and perfect temperature control. After pre-dispersion, fine dispersing takes place on agitated bead mills or three roll mills. Three roll mills typically need two to three passes to achieve the required particle size or coloristic properties. Feeding of the three roll mill is often by press out systems or pumps. Here, cleanability is one of the important advantages of the three roll mill. On only one machine is it realistic to produce small batches of different colors. Features like cleanability, no cross contamination, very small hold ups and defined stress are still unrepeated by any other technology. But mechanical roll pressing systems or even hydraulic systems are not comparable with the fully automated machines of today.

FIGURE 1 | Product flow at different roll speeds.

Roll 1

Roll 2

Roll 3

Function The basic function of the three roll mill is a differential speed between the three rolls. The difference between the second and the third rolls is two to four times higher than the difference between the first and the second rolls. The dispersion takes place in the second nip; the first nip regulates the feeding of the second “dispersing” nip. The rolls have to be positioned accurately. In cases where the viscosity and the tack of the product are high enough to create hydraulic pressure, the rolls have to be pressed together. If the viscosity is very low and the product is shear sensitive, the rolls should not press together. Due to the differential speed and the constant volume flow on the rolls, the first nip and the second nip have a similar ratio as the roll speed. This means if the rolls have to be positioned because of the low viscosity, the first and second nip will have different settings (Figure 1). The dispersion takes place in a shear field over the length of the roll. As long as the particles are smaller than the nip there is no impact to the particles in the suspension. This feature makes the dispersing process very uniform and also adjustable by pressure or position of the rolls. Using only shear stress, the single particle will not be affected. This means we do not change the shape, specific surface or size of the discontinuous phase. For many applications, this is very important – for example, metal pastes or functional ceramic pastes where we do not want to change the single particle size or the specific surface of the ceramic in suspension. Many raw materials are already in specification and should not be affected during the dispersion process; this means using only shear stress.

Process Parameters Remarks: • Drawing shows only the relation of the conveying amounts • nRoll1 < nRoll2 < nRoll3 Roll temperatures: • A colder roll takes more product. Roll 3 is 5K colder than Roll 2.

Figure 2 shows an overview of process parameters for a three roll mill. There are three groups of parameters – machine, method of operation and rheological behavior. The rheological behavior is the most important group but cannot always be influenced. The machine has to be able to

By Norbert Kern, Head of Process Engineering, Grinding & Dispersing Technologies | Buhler AG, Uzwil, Switzerland 46

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JULY 2011 | W W W . P C I M A G . C O M

handle a wide range of viscosities, either with very low line force or with an accurate roll positioning system. If the mill base can be adapted, this can optimize the process the most.

Design Features Due to different applications, the requirements for the roll design and pressing have changed over the last few years. For example, metal pastes need to be processed very gently in the beginning, and more aggressively at the end. Electronic materials are getting lower in viscosity because of very thin film applications, and need to be processed by roll positioning. There are two different roll designs to fulfill the new requirements. P-Rolls, with a guided cooling system, are very stiff and are specially designed for low line forces or accurate roll positioning (also called gap mode). For the complete line force range, the VIVA™ roll design offers full flexibility. The full line force range and also the flexibility in materials are unique features of the VIVA system (Figure 3).

New-Generation Three Roll Mill The Trias™ is the first fully automated production three roll mill with automated “pressure” mode and “gap” mode. The design allows the machine to operate on very low line force in the pressure mode or to change directly to the gap mode. Operating a three roll mill in the gap mode means to position the rolls very accurately and repeatably to each other. The Trias uses a pneumo-mechanic roll pressing control. Conventional hydraulic cylinders have a relatively high internal friction. This makes the control on the lower line force range especially difficult, or even impossible. The pneumo-mechanic roll pressing control is designed with a very low internal friction. This makes it possible to handle line forces down to 3-4 N/mm (Figure 4). The main part of the roll pressing is an eccentric shaft. A big rotation angle of the eccentric shaft results in a very small change of the axes positions. This means a high accuracy of the distance setting between the roll shafts (gap setting). The eccentric shaft multiplies the force about 20 times. This means a low force in the roll pressing results in a very high pressure between the rolls. This is why pneumatic can be used instead of hydraulic. A pneumatic step motor is used to change the angle of the eccentric shaft, which changes the distance between the roll shafts and the gap between the rolls. One step of the step motor changes the distance between the roll shafts by 1 micron. When working with gap, the control system of the Trias moves the step motors to the setting value. The machine doesn’t measure the actual gap between the rolls – it just moves the step motors to a setting value (increment), which corresponds to a certain position of the roll shafts. The value 0 increment is calibrated during the start-up of the machine and means that the rolls are just touching (almost without pressure). The maximum gap on the Trias 300/600 is 300 increments, which corresponds to a gap between the rolls around 0.3 mm without product. The force applied to the rolls with the eccentric shaft is measured with a force sensor placed in the connection

between the bearing units of the rolls on the cooling side. The control system checks the actual value of the line force with the force sensors and adjusts the position of the step motors to reach the setting values of the line force. If the pressure between the rolls changes (due to the product for

FIGURE 2 | Three roll mill factors of influence. Suggested by End User

Suggested by Supplier

Machine

Method of operation

Rheological behavior Mixture predispersion

Resources

• Crown differential rotational speed • Cooling knife

• Applied pressure • Parallel operation • Temperature control • Knife setting • Roll mill feeding

• Premixture type • Thickener type • Premixture • Pigment type temperature • Mixture ratio • Wetting rate

FIGURE 3 | VIVA rolls. • Reduced wall thickness

better heat transfer.

• Increased cooling efficiency. • Increased speed of third roll up to 550 rpm (22 – 37%). Full pressure range. 10–30% more output.

Thin roll sleeve (same material as before) Dynamic layer/intensive cooling Rigid roll core

Journal

FIGURE 4 | Principle of pneumo-mechanic control. • Mechanical adjustment of line pressure Automated version by pneumatic motor Manual version by hand wheel possible

Roll pressed

• Measuring of pressing force allows calculation of line pressure • Automated control allows roll adjustment via pressure (same as hydraulic principle) • Optional measuring of layer thickness on roll 3 allows constant gap setting • Constant gap over the whole process

1 2

3

4

5

1. Step motor for automatic adjusting 2. Pneumatic cylinder 3. Force sensor 4. Excenter 5. Hand wheel for manual adjusting

PA I N T & C O A T I N G S I N D U S T R Y

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New-Generation Three Roll Mills Meet Today’s Challenges

The Trias control system includes • graphic touch screen panel; • process visualization; • input and control of operation parameters like: roller temperature, roller speed, roller pressure, roller gap; • recipe database; • interface to higher-level host systems and to Buhler data logging software WinTrend; • automatic roller pressure and gap setting by input of the target value on the graphic touch-screen panel; • electronic controlled stepper motor; and • digital display of actual and target values on the graphic touch-screen panel.

FIGURE 5 | Roll pressing Trias.

Force sensor

Conclusion

Eccentric shaft

With new-generation three roll mills like the Trias, the success of this technology will continue. Clean room capabilities, high flexibility and high accuracy will open new opportunities. Reproducibility is one of the keys to be successful in any industry. Scale up from relatively small lab sizes to big production machines is possible in a fully automated plant environment. 䡲

Pneumatic step motor

example), the control system will measure it and readjust the position of the step motors to keep the line force constant. The very low friction in the pneumo-mechanic roll pressing allows it to start working in pressure mode at very low line force (5N/mm compared to 20-30N/mm on conventional hydraulic three roll mills) (Figure 5).

For more information, visit www.buhlergroup.com. This paper was presented at the 2011 European Coatings Congress, Nuremberg, Germany.

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oatings have been UV cured in industrial settings since the 1960s. The graphics industry was one of the first to adopt this technology, with a high-gloss coating on cards. Today, there are numerous industrial applications that utilize UV curing as the method of drying or polymerizing the coatings or inks, including the wood coating industry. The wood coating industry initially embraced UVcuring technology as a way to increase both productivity and performance, and more recently as a means to save energy and meet environmental regulations. Initially, all applications were based on 100% solids UV-curable products, coating mainly flat panels by roller coater. During the 1990s, UV-curable polyurethane dispersions in water (UV-PUD) were developed. PVC floor coating was the first industrial application. The flexibility, adhesion and stain resistance of these coatings made this new technology very successful. The low viscosity and the very low VOC of these dispersions also made them very attractive for spray, curtain and vacuum applications onto wood. In recent years, commercial UV curing has moved out of the factory and into the field, with numerous improve-

TABLE 1 | Recent improvements to UV-curing equipment. Feature

Purpose

Shutters – manual control or tied to movement of machine Instant on/off feature – tied to movement of machine Tip detectors Heat sensors Speed control – self propelled or speed gauge for manual propulsion Retractable handles Light weight Power supply 110, 230 or 380 V Emergency shut off/on handle Shielding Mandatory use of UV protective eye wear Use of clothing and creams to protect skin from stray UV light Cordoning off work areas Warning lights

Reduce accidental UV exposure if machine is lifted or moved Reduce possibility of floor damage

Reduce possibility of floor damage Improve process reproducibility Better clearance Maneuverability Fit local energy supply Safety Decrease eye and skin exposure

ments in UV-curing equipment enabling this transformation. Floor coatings are one of the main applications for field-applied UV-cured coatings. Today, field-applied or on-site floor coatings for wood are in several stages of commercialization. The benefits of UV-cured field-applied wood coatings are similar to factory-applied wood coatings: increased productivity and performance. In addition, the immediate cure aspect provides (1) an added benefit of quality, since the finish will not be damaged once it is cured, and (2) cost savings to the end user through immediate use. In this article, the performance of water-based fieldapplied UV-cured wood floor coatings is compared to that of conventionally cured wood floor coatings. The benefits and detriments of each curing technology are also reviewed. Additionally, several UV-cure processing and formulating variables are evaluated regarding their effect on coating performance.

Field- vs. Factory-Applied Coatings Applying and curing a wood coating in a factory is a wellcontrolled process. Moving this process to the field introduces many uncontrolled variables, which means that a robust coating and cure process are needed. Substrate variations are more common in the field, where wood composition, surface treatment, roughness, porosity and contamination are all potential challenges. The substrate is also larger than the UV-cure unit (unlike in the factory). UV leakage at the sides of the curing equipment can prematurely cure the coating at the edges of the cure path. This may cause changes in the surface appearance in this area. Also, care must be taken to ensure complete cure of all areas. Overlap criteria for the UV-curing unit are typically provided by the coating supplier to assist in achieving complete cure. Field-applied UV-curable wood coatings are applied like conventional wood coatings using a roller or T-bar applicator. This application method can result in coating thickness variations. Finally, the UV-cure unit is mobile and moves over the substrate. The distance from the UV-cure unit to the substrate and the speed of the UV-cure unit may both vary during the UV-curing process. The equipment for field-

By Dr. J. Arceneaux, Technical Manager, New Business Development; and James C. Smith, Applications Specialist, New Business Development | Cytec Industries, Smyrna, GA; G. Vanmeulder, Applications Specialist | Cytec Industries, Drogenbos, Belgium; and Dr. S. Smeets, New Business Development Manager Radcure Resins | Cytec Industries, Brussels, Belgium 50

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JULY 2011 | W W W . P C I M A G . C O M

applied applications has undergone many modifications and upgrades over the last years. There are at least seven manufacturers, each of whom has a unique construct for their machines. Some of the recent improvements to equipment are shown in Table 1. Many of these improvements address safety issues or process reproducibility. In general, however, it is the coating formulation that must be robust enough to overcome all of these challenges.

TABLE 2 | Comparison of water-based to 100% solids UV technology. 100% Solids UV Film-forming resin

Acrylated resin

Molecular weight Crosslink density

Low High

Cure mechanism

Free radical reaction

Water-Based UV vs. 100% Solids UV In recent years, water-based UV-curable raw materials have been developed in response to several challenges in 100% solids UV-curable formulations. This may sound contrary to one of the major benefits of UV-curable materials: no need to evaporate water or solvent. However, the main advantages of water-based UV-curable raw materials are their low viscosity (< 200 cP), and their ability to be diluted with water to obtain even lower viscosity. Several UV-curable applications, including sprayable wood coatings, currently utilize solvent to reduce their application viscosity to acceptable levels. Water-based UV allows the elimination of this solvent, and the accompanying disadvantages of VOCs, HAPs, flammability, etc. The use of water as a diluent also allows for thinner dry films than 100% solids UV, in which the wet film thickness equals the dry film thickness. This thinner dry film can provide an improved appearance to the coated substrate. The lower dry coat weight of water-based UV also allows for easier matting. Water-based UV polyurethane dispersions separate oligomer viscosity from molecular weight. This allows for the development of higher-molecular-weight materials. These UV dispersions develop lower crosslink densities than 100% UV because of their higher molecular weight. Both of these attributes combine to bring improved properties such as flexibility plus chemical resistance and hardness. Shrinkage is also reduced due to the lower crosslink density, and this results in better adhesion and appearance. The use of acrylated monomers as diluents detracts from the oligomeric properties in 100% solids UV, whereas in water-based UV, the oligomer properties are unadulter-

Diluent Co-solvents Skin irritation Viscosity Dry film thickness Gloss range Flexibility + hardness Chemical resistance Shrinkage Adhesion Tack free after water evaporation

Water-Based UV Acrylated medium MW PU Medium Medium Film coalescence + water evaporation + free radical reaction

Acrylated monomer No Maybe High High 20-90 Difficult High High Difficult No

Water Maybe No Low Low 5-80 Easy High Low Easy Yes

ated. Many acrylated diluting oligomers can be skin irritants. These diluting oligomers are also more mobile than the oligomers, and can migrate into wood pores, where UV cure may not occur. The use of water as a diluent can eliminate both of these concerns. Many of the water-based UV oligomers are tack free after drying, but before UV cure. This property provides coatings that are more resistant to damage and dust contamination before UV curing. If damage does occur, the dried coating can be buffed to remove the damage before it is UV cured. It also allows the application of a second coat after drying but before UV curing the first coat, eliminating a UV-curing step. Table 2 summarizes the comparison of water-based UV technology to that of 100% solids UV technology.

Conventional and UV-Curable Technologies Polyurethanes (PUs) make up the majority of wood floor finishes, and include 1K oil modified, 1K waterborne, and

TABLE 3 | Summary of coating types, properties and dry times. 1K OilModified PU Cure type Pot life (hours) Sealer/stain coats (# recommended) Topcoats (# recommended) Dry time between topcoats (hours) Time to light traffic (hours) Time to rug replacement (days) VOC (g/L) US definition of VOC Flashpoint (°C)

1K 2K Waterborne Waterborne PU PU

2K Waterborne PU

2K Conversion Varnish

Oxidative

Oxidative

Aziridine

Isocyanate

n/a

n/a

8-24

4-6

Acid catalyzed 8

0-1

0-1

1-2

1

2-3

2-4

1-3

8-12

2-6

24

Oil

Wax

Oxidative

1K WaterBased UV PU UV

n/a

n/a

n/a

0

0

1

2

1-3

2-3

2-3

2-6

1-3

2-3 Buffing; 3-16 after final

24

24

24

12

24-48

4

14

7-14

7-14

7

7

7

Overnight

450-550

220-350

235-390

240-350

550

125

470-550

<200

43

>100

>100

>100

19

64

40

>100

2 Buffing

PA I N T & C O A T I N G S I N D U S T R Y

2-4 Immediate after UV cure Immediate after UV cure

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51

Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring

TABLE 4 | Composition of UV water-based floor finishes. Product

Source

UCECOAT® A UCECOAT B Water Ammonium hydroxide (28%) GASIL® 23F ADDITOL® VXW 4973 Butyl Carbitol BYK® UV3500 ADDITOL BCPK

Cytec Cytec

Matte Coating (%) Gloss Coating (%)

Cytec PQ Corporation Cytec Dow Chemical BYK Cytec

89.3 0.5 0.5 3.0 0.2 1.0 2.0 3.5

93.3

0.2 1.0 2.0 3.5

Purpose Main binder Main binder Diluent for viscosity/pH adjustment pH adjustment Matting agent Anti-foam additive Coalescing agent Flow and leveling additive Photoinitiator

Floor finish thickness, wet (μm) (*) 125-175 Floor finish thickness, dry (μm) 47-66 Application T-bar or flat pad UV Dose to get mar-free surface 300 (mJ/cm2) (*) The wood panels should be stained/sealed before topcoat application. Exhaustive testing of stains/sealers for compatibility and performance has not been done. Waterborne sealers tend to show better performance.

2K waterborne. Swedish finishes (conversion varnishes) have very low usage due to regulatory concerns, and oils and waxes are still used in limited markets to get a beautiful, hand-rubbed appearance. Water-based UV-curable polyurethanes are just entering the marketplace. All of the polyurethanes, including UV-curable, demonstrate a combination of properties that are beneficial to wood floor coatings, such as high surface hardness, very good chemical resistance, toughness, excellent lowtemperature flexibility, very good abrasion resistance and extreme durability. These properties are the result of the polyurethane structure, which consists of both hard and soft segments within the same polymer chain. In order to develop the properties noted above, the polyurethanes must have some degree of crosslinking. This crosslinking can be provided through several different mechanisms: auto-oxidation, isocyanate reactions, aziridine reactions or UV curing. The isocyanate and aziridine chemistries are twocomponent systems with limited pot life, while the other polyurethane chemistries are one-component systems with unlimited pot life. The conversion varnish is a twocomponent system, and the oils and waxes are one-component systems. Two-component systems with limited pot life can result in wasted product, and deficiencies in product performance due to improper mixing.

TABLE 5 | Coating properties of conventional and UV floor finishes. Property

Method

Cross-cut adhesion Pencil hardness Chemical resistance (spot test) Solvent resistance (MEK double rubs) 60° Gloss

ASTM D 3359-07 ASTM D 3363-05 ASTM D 1308-02 ASTM D 5402-06 ASTM D 523 Drag a standardized coin on edge across the coated wood using firm pressure. Impact the coated wood with the edge of a black shoe heel, by using a backward motion of the leg.

Coin test

BHMR (Black Heel Mar Resistance)

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JULY 2011 | W W W . P C I M A G . C O M

The VOCs of floor finishes have become important in recent years. The principal area of concern has been the emission of VOCs from coatings during manufacturing, drying and curing processes. Therefore both Europe and the United States have introduced legislation that limits the emission of VOCs in both paint manufacturing and application processes. More of the conventional floor coatings are being adapted or withdrawn from the market to meet the legislation. All wood floor finishing is a multi-coat system. Three to four coats are typical, and may include stains, sealers and finishes (topcoats). The stains and sealers may be solventborne or waterborne, and are typically fast drying. The topcoats are applied after the stain/sealer coats. The drying time of the topcoat varies from around three hours for waterborne systems and conversion varnishes to around 10 hours for oil-modified polyurethanes. Drying is not necessary for oils and waxes, but buffing is done between topcoats. The dry time is the time required between the applications of the multiple topcoats. After the final topcoat has been applied, the coating must be allowed to fully develop its performance properties. Since some of these times can be quite long, recommendations on return of the floor to service are classified as time to light traffic and time to rug replacement. For UV-cure finishes, all of these times are immediately after UV cure. This provides a substantial advantage over all of the other technologies, but especially the other polyurethane technologies, which recommend 24 hours before light traffic, and 7 to 14 days before rug replacement. Table 3 summarizes the data presented above, which were obtained from product brochures and data sheets. Missing from these data sheets is specific information on product performance. Other than a few data sheets that list data on pendulum hardness and abrasion no other performance information is provided.

Test Procedure and Floor Finishes In this article the product performance of a number of commercial conventional wood floor finishes is discussed

Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring

and compared to starting-point formulations for UVcurable water-based floor finishes based on UCECOAT® UV PUDs. A 1K oil-modified polyurethane, 1K waterborne polyurethane, and 2K waterborne polyurethanes (aziridine cure and isocyanate cure) were evaluated. Additionally, the properties of UV coatings were assessed regarding development over time, for single versus multiple topcoats, and for UV exposure and photoinitiator concentration.

TABLE 6 | Property development over time for two different water-based UV finishes.

Adhesion (crosshatch) Matte Gloss Coin test Matte Gloss Mustard resistance (30 min spot test) Matte Gloss Pencil hardness Matte Gloss Solvent resistance (MEK double rubs) Matte Gloss

Time After UV Cure 4h 8 h 24 h

Initial

1h

48 h

72 h

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

5 5

5 5

5 5

5 5

5 5

5 5

5 5

3B 3B

3B 3B

3B 3B

3B 3B

3B 3B

3B 3B

3B 3B

200+ 200+

200+ 200+

200+ 200+

200+ 200+

200+ 200+

200+ 200+ 200+ 200+

5: No coating lift/distortion/stain 4: No coating lift/slight distortion/slight stain 3: Slight coating lift/moderate distortion/moderate stain 2: Moderate coating lift/severe distortion/severe stain 1: Severe coating lift/complete stain (*) distortion

TABLE 7 | Properties of a single-coat vs. two-coat systems (individually cured and simultaneously cured).

Gloss at 60° Coin test Pencil hardness BHMR Solvent resistance (MEK double rubs) Chemical resistance (24 h spot test) Mustard Betadine Navy RIT dye (RIT Dye Company) Xylene Ethanol Isopropanol

Single Coat

Two Coats Individually Cured

Two Coats Simultaneously Cured

17 4-distortion 4B 5

15 4-distortion HB 5

19 4-distortion HB 5

200+

200+

200+

5 5 4 (5 after 30 min) 5 5 5

5 5 4 (5 after 30 min) 5 5 5

5: No coating lift/distortion/stain 4: No coating lift/slight distortion/slight stain 3: Slight coating lift/moderate distortion/moderate stain 2: Moderate coating lift/severe distortion/severe stain 1: Severe coating lift/complete stain

54

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JULY 2011 | W W W . P C I M A G . C O M

5 5 4 (5 after 30 min) 5 5 5

Oak wood panels were sanded and then sealed with two coats of water-based sealer according to the manufacturer’s directions. (Nanoshield™ Sealer, Zinsser Co., Inc.) Several conventional floor finishes were used as received from the manufacturers. The directions for use were followed for each of these products. The composition of the UV water-based floor finishes is shown in Table 4. The UV floor finishes were cured using a laboratory cure unit from HID Ultraviolet, LLC. This laboratory cure unit consists of a mobile curing unit (Bulldog 15-3000) equipped with a 100 watts/cm medium pressure continuous wave Xenon lamp. It is mounted on a conveyor system with variable belt speed to enable ease of laboratory work. The UV water-based floor finishes were UV cured at 350 mJ/cm2, corresponding to a walking speed of 15 meter per minute. Coating properties of the conventional and UV floor finishes were determined as shown in Table 5. These properties were evaluated at several points during the cure cycles of the conventional coatings, and over 0-72 hours for the UV coatings.

Test Results Property Development vs. Time In 100% solids UV-curable coatings, shrinkage upon cure can be significant, which can then develop stress in the coating. As the coating relaxes over time, this stress is removed, and the coating properties can change as a result. Many refer to this as “dark cure”, although it is doubtful that additional curing is taking place. In water-based UV-curable coatings, shrinkage is greatly reduced, so stress build in the coating is diminished. This results in coating properties that do not change over time. Table 6 demonstrates this, by showing that the properties of two different water-based UV finishes are the same immediately after cure and over a period of 72 hours. As mentioned earlier, the time to light traffic and time to rug replacement differ for the different conventional floor finishes. As shown in Table 6, for UV water-based finishes, all of these times are immediately after UV cure. This provides a substantial advantage over all other technologies, but especially other polyurethane technologies, which recommend 24 hours before light traffic, and 7-14 days before rug replacement.

Single-Coat vs. Two-Coat System Since floor finishes typically use multiple coatings, the effects of the number of UV coatings and their curing processes were investigated. For water-based UV coatings that are tack free before cure, a second coating may be applied as soon as the first coating has dried. An intermediate UV-cure step is not required, but may be used if desired. In order to facilitate intercoat adhesion, an intermediate cure step should use less energy than that required for full cure (typically 1/3 of full cure). If the first coating is fully cured, another way to ensure intercoat adhesion is to lightly sand before application of the second coating. Table 7 shows that the properties are essentially unchanged for a one-coat system, a two-coat system that has been individually cured, or a two-coat system that

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Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring

TABLE 8 | Test results over different exposure times for matte UV water-based finishes.

Cure speed (m/min) Adhesion 1% PI 3.5% PI Coin test 1% PI 3.5% PI Mustard resistance (30 min spot test) 1% PI 3.5% PI Mustard resistance (24 h spot test) 1% PI 3.5% PI Ethanol resistance (40 min spot test, covered) 1% PI 3.5% PI Solvent resistance (MEK double rubs) 1% PI 3.5% PI

UV Exposure (mJ/cm2) 150 200 250

50

100

300

350

>30

>30

>30

25

22

18

15

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

5B 5B

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

4 (*) 4 (*)

5 5

5 5

5 5

5 5

5 5

5 5

5 5

4 4

4 5

4 5

5 5

5 5

5 5

5 5

1-lift 3-lift

1-lift 5

5 5

5 5

5 5

5 5

5 5

60 195

130 200+

150 200+

150 200+

195 200+ 200+ 200+

5: No coating lift/distortion/stain 4: No coating lift/slight distortion/slight stain 3: Slight coating lift/moderate distortion/moderate stain 2: Moderate coating lift/severe distortion/severe stain 1: Severe coating lift/complete stain (*) distortion

200+ 200+

has been simultaneously cured. The only differences are small changes in gloss, and a softer coating for a one-coat system. Since both time and energy can be saved by simultaneously curing a two-coat system, and there is no effect on coating properties, this is the recommended procedure if two UV floor finishes are desired.

Property Development vs. UV Dose The performance of a UV-curable finish is strongly related to the radiation energy (UV dose) that is necessary to polymerize (cure) the finish. Whereas UV curing of wood finishes in factory settings is well-controlled, UV curing in the field introduces many uncontrolled variables. As such it is important that the cure window is wide enough without influencing the UV finish properties. Table 8 provides data on matte UV water-based finishes containing 1.0% or 3.5% photoinitiator that were UV cured at exposures from 50 mJ/cm2 to 350 mJ/cm2. These exposure levels correspond to linear speeds of 15 m/min to greater than 30 m/min. Adhesion, the coin test, and 30 min mustard resistance were the same at all exposure levels. When the mustard resistance spot test was extended to 24 hours, differences were seen. An ethanol resistance spot test and solvent resistance also showed differences. For systems containing 3.5% photoinitiator, the coating properties are unchanged from speeds of 15 m/min to > 30 m/min. The matte formulation allows greatly different cure speeds to provide the same coating properties (wide cure window), and thus provides flexibility for the contractor who applies and cures the coating. Formulations containing 1.0% photoinitiator show a decrease in coating properties beginning at 250 mJ/cm2

TABLE 9 | Test results for floor finishes over time. Technology Gloss 60° 1 day 7 days 14 days Adhesion 1 day 7 days 14 days Coin resistance 1 day 7 days 14 days BHMR 1 day 7 days 14 days Pencil hardness 1 day 7 days 14 days Solvent resistance 1 day 7 days 14 days 56

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1K Oil-Modified PU Oxidative Cure

1K Waterborne PU Oxidative Cure

2K Waterborne PU Aziridine Cure

2K Waterborne PU Isocyanate Cure

1K Waterborne UV PU UV Cure

51 35 46

34 27 31

48 48 54

25 21 20

26 25 25

2-lift 5 5

5 5 5

5 5 5

5 5 5

5 5 5

1-lift 4-distortion 4-distortion

1-lift 1-lift 2-distortion

4-distortion 4-distortion 4-distortion

4-distortion 4-distortion 4-distortion

4-distortion 4-distortion 4-distortion

5 5 5

2-distortion 5 5

5 5 5

5 5 5

5 5 5

7B 5B 4B

7B 4B 4B

7B 4B 4B

4B 4B 4B

4B H H

195 140 195

10 20 20

120 200+ 195

30 135 150

200+ 200+ 200+

JULY 2011 | W W W . P C I M A G . C O M

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Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring

TABLE 10 | Test results for resistance to common household chemicals. Chemical Resistance (with Cottonball, Covered)

1K Oil-Modified PU Oxidative Cure

1K Waterborne PU Oxidative Cure

2K Waterborne PU Aziridine Cure

2K Waterborne PU Isocyanate Cure

1K Waterborne UV PU UV Cure

5 5 5

5 5 5

4-stain 4-stain 4-stain

4-stain 5 4-stain

5 5 5

4-stain 4-stain 4-stain

4-stain 4-stain 4-stain

3-stain 3-stain 3-stain

3-stain 3-stain 3-stain

5 5 5

5 5 5

5 5 5

5 5 5

4-stain 5 4-stain

5 5 5

5 5 5

4-stain 4-stain 4-stain

3-stain 3-stain 3-stain

3-stain 3-stain 3-stain

5 5 5

3-stain 5 4-stain

3-stain 5 5

2-stain 3-stain 3-stain

3-stain 4-stain 3-stain

5 5 5

2-stain 3-stain 2-stain

1-stain 2-stain 2-stain

1-stain 1-stain 1-stain

1-stain 2-stain 2-stain

4-stain 4-stain 4-stain

1-lift 1-lift 1-lift

1-lift 3-distortion 1-lift

4-stain 5 4-stain

4-distortion 5 4-stain

5 5 5

1-lift 1-lift 1-lift

1-lift 1-lift 1-lift

4-stain 4-stain 3-stain

2-distortion 4-stain 3-stain

2-distortion* 4-stain* 4-stain*

1-lift 1-lift 1-lift

1-lift 1-lift 1-lift

4-stain 4-stain 3-stain

2-distortion 4-distortion 3-stain

4-distortion 5 5

5 5 5

5 5 5

5 5 5

5 5 5

5 5 5

4-stain 5 5

2-stain 4-stain 2-stain

5 5 5

5 5 5

5 5 5

3-stain 4-stain 4-stain

1-stain 1-stain 1-stain

4-stain 4-stain 5

2-stain 2-stain 2-stain

4-stain* 3-stain* 3-stain*

5 5 5

4-distortion 5 5

5 5 5

5 5 5

5 5 5

5 5 5

4-distortion 5 5

5 5 5

5 5 5

5 5 5

Mustard, 30 min 1 day 7 days 14 days Mustard, 24 h 1 day 7 days 14 days Betadine, 30 min 1 day 7 days 14 days Betadine, 24 h 1 day 7 days 14 days RIT Dye (navy, undiluted), 30 min 1 day 7 days 14 days RIT Dye (navy, undiluted), 24 h 1 day 7 days 14 days Xylene, 24 h 1 day 7 days 14 days Ethanol (99.5%), 24 h 1 day 7 days 14 days IPA (99%), 24 h 1 day 7 days 14 days Water, 24 h 1 day 7 days 14 days Formula 409, 24 h 1 day 7 days 14 days Windex, 24 h 1 day 7 days 14 days Vinegar, 24 h 1 day 7 days 14 days Olive oil, 24 h 1 day 7 days 14 days 5: No coating lift/distortion/stain 4: No coating lift/slight distortion/slight stain 3: Slight coating lift/moderate distortion/mode 2: Moderate coating lift/severe distortion/severe stain 1: Severe coating lift/complete stain (*) 30 min stain exposure gave evaluation of 5.

58

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Water-Based, Field-Applied UV-Curable Topcoats for Wood Flooring

for solvent resistance, 150 mJ/cm2 for 24 hour mustard resistance, and 100 mJ/cm2 for ethanol resistance. Based on these results, formulations containing 1.0% photoinitiator have a narrow cure window, from 15 to 18 m/min. Contractors would have to be more careful to ensure complete cure with this wood finish. In optimizing the coating formulation, the photoinitiator concentration should be chosen to meet both cost constraints and the desired width of the cure window.

Performance Results The gloss of all the tested floor finishes is fairly stable over time, as shown in Table 9, with the UV-curable coating demonstrating the most stable gloss. Adhesion is basically the same for all floor finishes. A loss of adhesion is only seen in the 1 day result for the oil-modified polyurethane. In general, all of the 2K floor finishes perform the same, and better than the 1K systems in the coin test. Black heel mark resistance is good for all finishes, with only the 1K waterborne polyurethane showing poor performance at 1 day. The UV-curable finish is harder than the other floor finishes, and also has better solvent resistance. The resistance of floor finishes to a number of common household chemicals is shown in Table 10. The UV-curable floor finish shows no loss of adhesion, coating, distortion or coating stain when exposed for 24 h to mustard, betadine, xylene, water, Formula 409®, vinegar or olive oil. It shows the same results for

30-min exposures to undiluted navy RIT® dye, ethanol, isopropanol and Windex®. Some conventional floor finishes show good resistance to some chemicals, but none show the broad chemical resistance of the UV-curable floor finish.

Conclusion The performance of field-applied UV-curable floor finishes based on new UV-curable polyurethane dispersions has been compared to that of conventional floor finishes. UV-curable floor finishes show better hardness, solvent resistance and chemical resistance then the conventional floor finishes. This improved performance is obtained immediately after the UV-curing step. No extended cure time is needed for the development of properties compared to conventional floor finishes. The immediate cure aspect provides an added benefit of quality, since the finish will not be damaged once it is cured, and cost savings to the end user through immediate use. These properties are also evident in either a one- or a two-topcoat system; the two-topcoat system may be processed in a number of ways without affecting coating properties. The width of the cure window for UV-curable floor finishes can be adjusted to allow variation in cure parameters as required for use in field-applied settings. 䡲 This article was published in the April 2011 issue of PPCJ magazine.

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JULY 2011 | W W W . P C I M A G . C O M

Mason Color’s high performance pigment technology for coatings provides the ultimate in heat resistance, UV durability, and chemical resistance. Our mixed metal oxide pigments meet the most exacting color and durability requirements of the defense, architectural, stove and heating products, and roofing industries. These pigments add vibrant color to building facades, stove equipment, exhaust parts and outdoor furnishings and equipment. These advanced technology pigments can be incorporated into any coating platform including powder coatings, electrocoat, high solids and waterborne paints.

Mason Color Works, Inc. A History of Pigment Technology Excellence Mason Color Works has been manufacturing high temperature, inorganic pigments since 1842. For more than 40 years Mason Color has been a global supplier of high performance pigments to all sectors of the ceramic industry including pottery, artware, bricks, sanitaryware and roofing materials. In the last 45 years, Mason Color has expanded into the high technology Investment Casting Industry. Our ISO Compliant Cobalt Aluminate products are integral in the manufacturing jet turbine blades and medical devices. In the 1990s heralded the emergence of the fireplace gas log industry and Mason Color's participation as a supplier of high quality, high temperature pigments for this use. Soon thereafter, the Swimming Pool and Spa colorant industry embraced Mason's pigment technology. Our high quality pigment exceed the demands for resistance to punishing UV energy and the aggressive chemicals used in swimming pools. Our fully outfitted Powder Coating Laboratory and skilled technicians will help you choose the perfect color for your most demanding requirements.

Expanding the Functionality

M

anufacturers f t constantly t tl strive t i to t make coatings and adhesives more durable and functional. Recently, some have discovered that a timetested, versatile technology provides opportunities to include high-performance additives that help those products more effectively beautify, protect and seal. Microencapsulation technology makes it possible to add materials that would have shorter useful lives or be outright incompatible with the base product if mixed conventionally. Microencapsulation already enables coatings to be infused with longer-lasting biocides for protection against mold and mildew, and also creates potential for extraordinary new applications – like a wall coating that helps moderate the temperature of a room, or a finish that can self-heal if scratched. Microencapsulation effectively seals an additive within a microscopic wall so that it remains isolated from the base product until it is released in response to some stimulus. While proven for decades in other industries, microencapsulation is just now gaining attention for coatings and adhesives. Its potential appears limited only by the collective ingenuity of product manufacturers and microencapsulation experts.

Chemical New Uses for Microencapsulation Microencapsulation is the process of putting a microscopic wall around a core substance. To envision this technology more easily, think of a candy-coated chocolate as a microcapsule. In this case, chocolate (the core payload) is held inside the candy shell. To prevent melting chocolate from making a mess all over your hands while eating the candy, the payload is not released until you break the capsule with your teeth, or let the moisture in your mouth slowly dissolve it. This provides the best of both worlds: the taste of chocolate without the mess. Now think of all of that happening at a microscopic level. Microencapsulation was invented for one specific purpose: to find an alternative to ink ribbons used inside cash registers. NCR Corporation scientists invented and patented the process known as chemical microencapsulation. They turned to Appleton Papers to develop a workable microcapsular coating that led to the introduction of carbonless paper in 1954. The Appleton scientists who continued to work with microencapsulation technology recognized the potential for microencapsulation to extend to other applications beyond carbonless paper. However, the ongoing growth and development of the carbonless paper industry kept those scientists focused on supporting Appleton’s primary product for decades. More recently the scientists with expertise in chemical microencapsulation have begun to use their unique and extensive expertise in microencapsulation to develop specific and often proprietary product solutions in the consumer products industry. At Appleton, these efforts gave birth to Encapsys ®, a division within the company that uses a collaborative approach between our own scientists and partner companies to develop smart chemistry solutions. Procter & Gamble was one of the first companies to consider using the potential of microencapsulation to manufacture a better product, and they turned to Encapsys for help. Working closely with P&G, the Encapsys team created microcapsules that are capable of performing as needed in P&G’s products, helping to deliver a heightened consumer experience while also meeting their business needs. P&G provides the need for microencapsulation technology, and Encapsys delivers the solutions. Encapsys recently used the same approach with a noted performance materials manufacturer and entered into a supply agreement to develop and supply a microencapsulated biocide to select marketplaces worldwide.

By Ted Goodwin, Vice President Business Development, and Irenee Philippe, Group Business Development Manager | Encapsys Division, Appleton Papers Inc., Appleton, WI 62

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JULY 2011 | W W W . P C I M A G . C O M

of Coatings Through

Microencapsulation Open iinnovation O ti and d collaboration ll b ti b between t microi encapsulation companies and producers of coatings and adhesives could lead to new solutions for old problems or to product opportunities that were believed to be impossible. The only way to find and recognize these solutions and opportunities is through an open dialogue between collaborative partners.

Potential Opportunities to Expand the Capabilities of Coatings When mixed conventionally, additives like antimicrobial agents, fungicides or mildewcides in architectural coatings are typically short-lived. Encapsulation has demonstrated the potential to extend the release profile and allow the coatings to protect the surface for years instead of only weeks or months. Similarly, corrosion inhibitors in paint could be encapsulated to release only under specific conditions, such as a certain pH level or cumulative exposure to ultraviolet light. Released only as needed, the inhibitor could protect significantly longer than a traditional finish. Chemical microencapsulation could, potentially, benefit the coatings industry in a variety of other ways that enhance products more subtly. These could save many manufacturing companies a great deal of money and also create better products for consumers.

Keeping Ingredients Separated Microencapsulation can also enable mixing of substances that would separate, clump together, or react chemically if mixed in conventional ways. An obvious example would be mixing an additive with paint. Encapsulation could allow the substance to reside in the paint until the time of application, when capsule breakage or some other trigger would release it.

Protecting Product Utility Microencapsulation could also protect additives that would otherwise slowly deteriorate in solution over time. No longer needing to allow for losses during shipment and storage, the manufacturer could add the optimum amount, which could reduce costs and extend the product’s shelf life.

Enhancing Consumer Safety Another potential benefit of microencapsulation is enhanced safety in product handling. Additives that in raw form might pose safety concerns could be isolated in capsules engineered for release only after the product was applied and exposed to an appropriate trigger. Human exposure would be reduced at both the production and end-use levels.

Self-Healing Self Se lf Healing Coatings Microencapsulation might provide self-healing for scratches to flooring, car or boat finishes, furniture and appliances, which can be difficult to detect and costly to repair. Here, a scratch would release microencapsulated material that would re-seal the break in the coating and protect the substrate.

Microencapsulation can also enable mixing of substances that would separate, clump together, or react chemically if mixed in conventional ways. The encapsulated material could be more of the same paint or varnish used in the finish, or a protective substance that would simply exclude moisture to prevent rust or other deterioration. The infused coatings could be designed to last the life of the substrate. Similarly, plastic or fiberglass could be impregnated so that in case of a minor break, the material would fuse back together, providing enough strength to prevent outright failure until the time of repair.

Protecting Brand Owners and Consumers Beyond providing physical protection, microencapsulated ingredients in inks or coatings could fulfill various marking and indicating functions, showing when an object has been damaged or has taken an impact, even when evidence of the event might not otherwise show. For example, a shipping container that has been dropped or struck might bear no obvious signs of damage although something inside is broken – but an encapsulated pigment released on impact with the surface would leave an obvious mark, alerting the recipient to inspect the container before accepting it. In similar fashion, an encapsulated pigment with a temperature trigger could indicate that a container of medicine or other perishable good had encountered excessive heat during storage or shipment. The same basic concept also could apply to indicating impacts to cars and boat hulls, or to lift trucks and other industrial vehicles in factories and warehouses. Closer to the consumer level, a motorcycle or bicycle helmet could show a mark and/or emit a scent if an impact caused a crack that would compromise its integrity. PA I N T & C O A T I N G S I N D U S T R Y

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Expanding the Functionality of Coatings Through Chemical Microencapsulation

Microencapsulation also has potential to support brand protection and product authentication. Possible applications include: • Validating the brand identity or age of a coating in assessing warranty claims. • Tracing a coating back to a specific production lot. • Using a specially formulated coating or ink as a signature to distinguish genuine products from counterfeits. • Making packaging adhesives tamper-evident, so that they release a color or aroma if a seal is broken.

Helping to Regulate Temperatures Looking to even more advanced applications, microencapsulation could make a paint or plaster that works in concert with building heating and cooling systems possible. Here, coatings would be infused with capsules containing a phase-change material – a substance that changes between solid and liquid phases at temperatures commonly encountered in indoor spaces. Changes in phase absorb or release heat energy while the temperature stays constant – for example, a glass of water containing ice cubes remains at 32 ºF until the ice is melted. In the same way, microencapsulated phase-change material added to plaster and applied to a wall would absorb the energy of sunlight through the windows, moderating the sun’s effect on the room’s temperature. Then, at night, the phase change would release the energy, slowing the room’s cooling. The net effect would be to keep the room temperature more consistent and comfortable, save energy, and conceivably reduce the size of the furnace or air conditioner needed for the space.

Collaborate to Innovate These current and potential applications most likely mark just the beginning of possibilities for chemical microencapsulation in the coatings industry. Success in generating ideas and bringing them to market depends on collaboration between brand owners/product manufacturers and microencapsulation innovators. The microencapsulation innovator relies on the customer’s product knowledge and market insight, while the customer takes advantage of the depth and breadth of the encapsulation company’s technical expertise and manufacturing capability. The two working together can produce innovations faster and more effectively than either party could alone. Coatings and adhesives suppliers seeking to create new markets or gain competitive advantage can benefit from considering microencapsulation and the potential it can provide. When the right partners combine the necessary market insight and technical savvy, the possibilities are almost limitless. 䡲 For more information, visit www.encapsys.com.

EQUIPMENT SHOWCASES

888 E. Belvidere Rd. Grayslake, IL 60030

www.hockmeyer.com

NANO DISPERSION RESEARCH EMI laboratory Mini Mills are ideal for producing realistic Nano dispersion samples for product research, technical service & quality control applications. These self pumping & self contained mills can wet mill samples as little as 25 ml’s, providing results that will answer dispersion questions quickly with minimum amounts of raw materials. Investigating Nano dispersions can be done using 0.05 mm & larger grinding media which are capable of producing sub-micron particles. Ideal for paints, inks, colorants, chemicals & industries requiring fine particles. Pilot scale and production mills are also available.

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Lab & Production equipment available. Contact EMI Mills to arrange a test today! Tel: 847-548-8224 64

Because the microcapsules would not break, the phase-change material in the plaster stays contained and could conceivably function for decades. In a similar way, phase-change coatings could be applied to upholstery to make furniture more comfortable, to the fabric of high-performance athletic clothing to help keep wearers warm or cool, or to computer batteries or electronic components to moderate temperature variations.

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E-mail: [email protected]

JULY 2011 | W W W . P C I M A G . C O M

MODEL 850 Myers Model 850 shows improvements in product quality and mixing time. The dual shaft, four-blade unit outperforms standard dispersers in many instances: Faster pigment loading, less heat buildup, better dispersion, improved particle size and less air entrapment.

Myers Engineering, Inc. A Leader in Mixing & Dispersing for over 60 Years. 323.560.4723 www.myersmixer.com [email protected]

“Great overview of new technologies and trends,” 2010 Attendee

98% 97%

of attendees said they would recommend the 2011 event to a colleague or co-worker.

were extremely satisƤed with CTT 2010.

92% of attendees were extremely satisƤed with the presentations at CTT 2010.

SEPTEMBER 13-14, 2011 CTT provides a global, resource-rich environment where attendees can engage with industry experts to learn about how new products and developments will improve coatings formulation. This affordable, one and a half day live event allows formulators to customize their educational and networking experience through concurrent technical sessions and an interactive exhibit hall.

Q

OAK BROOK, IL

2011 KEYNOTE COATING RESINS AND ADDITIVES – A NEW GLOBAL PERSPECTIVE DR. RICHARD D. JENKINS, GLOBAL GROUP PRESIDENT, ARKEMA COATING RESINS

COATINGS, TRENDS & TECHNOLOGIES 2010 SOLD OUT WEEKS IN ADVANCE. DON’T MISS YOUR OPPORTUNITY TO ATTEND IN 2011.

“Great conference – well organized, excellent topic coverage, useful networking opportunities,” 2010 Attendee

THIRTY PAPERS TO BE PRESENTED ALONG TWO DIFFERENT TRACKS HERE IS A SAMPLE OF SOME OF THE PAPERS THAT WILL BE PRESENTED SESSION TOPICS INCLUDE: Bayer MaterialScience Dow Coating Materials Matheson Clariant Corporation BASF Encapsys

(a division of Appleton Papers Inc.)

Keyland Polymer Ltd. Nanophase Technologies Corporation

PRODUCERS

Waterborne Polyurethane Technology in Corrosion-Resistant Coating Resins Performance Comparison of Waterborne and Solventborne Epoxy Coating Systems for Heavy-Duty Applications Eliminating Powder Agglomeration and Melting During the Grinding Process Colored Pigments: Chemistry & Performance - A Technical Presentation Rapid Property Development Acrylic Polyols New Uses for Microencapsulation in Coatings Formulations Opportunities for UV-Curable Powder Coatings Improved Weatherability of Translucent Wood Stains Through Nanotechnology

CURRENT EXHIBITORS

www.coatingsconference.com

C LASSIFIEDS EQUIPMENT

POSITIONS AVAILABLE

HIGH VISCOSITY DISPERSERS

TECHNICAL SALES MGR. – COATINGS We need a professional technical sales manager that wants their contributions to impact on our company and re¾ect their level of engagement with us. Do you share our brand values of global partner/ local presence; trustworthy partnerships; committed to sustainability; innovated and driven by passion? You will introduce new products, de½ne methods of promoting new and existing products, communicate the unique position that separates them from their competition, identify opportunities and through our local applications laboratory translate them to sales growth and ensure the most appropriate sales channels are effectively used.

New single shaft disperser for higher viscosities! • No need for a dual-shaft mixer in many applications • Top quality • Proven “Bow Tie” agitator

Salary is commensurate with experience.

R&D Manager – Ames, Iowa Colorbiotics, a unit of Becker Underwood, is the leading global manufacturer of colorants, specialty coatings and patented applications for coloring wood fiber, rubber and aggregate. We need someone to drive and manage the global product development process from concept to commercialization.

For complete details visit: www.pcimag.com/classifieds 68

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EQUIPMENT CORPORATION A leader in the grinding and dispersion industries New & Used Equipment Dispersers • Mills • Mixers • Tank & Tote Washers • Particle Size Analysis • Vessels Visit us at www.hockmeyer.com or call us at 252-338-4705 Wanted to purchase: Used Dispersers & Mixers

JULY 2011 | W W W . P C I M A G . C O M

TM

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The ideal candidate will have a strong coatings formulating background, is a respected member in coatings associations, have a solid coatings industry network and strong track record of accomplishments in sales / marketing to the coatings industry. Your candidacy will leap to the top if you’ve also got a strong track record of success in managing distributor networks and market development projects.

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We are Nubiola USA an international, family-owned company based in Atlanta that produce and market an extensive range of inorganic pigments and anticorrosives. You will join a company that seeks your involvement in growing the business that has manufacturing facilities in Spain, Colombia, Romania, India and joint venture in China.

Send us a copy of your resume along with a half-page summary of your most signi¿cant accomplishments to [email protected]. We think your summary is much more important than your resume and will read it ½rst.

EQUIPMENT

UHMW Poly

www.connblade.com

(814) 723-7980

Asia Pacific Coatings Show 2011 Marina Bay Sands, Singapore 14 – 15 September 2011 THE LEADING COATINGS EVENT IN SOUTH EAST ASIA & THE PACIFIC RIM

www.coatingsgroup.com BOOK YOUR STAND TODAY Contact: Jeff Montgomery Tel: +44 (0)1737 855 078 Email: [email protected]

Organised by:

Sponsored by:

Kez Chen Tel: +44 (0)1737 855 578 Email: [email protected] www.polymerspaintcolourjournal.com

C LASSIFIEDS EQUIPMENT

PRODUCTS & SERVICES

RECRUITMENT SERVICES Specializing in paint/coatings industry. Seeking passionate, high-impact professionals for nationwide positions. Send your resume in confidence to: Spencer M. Hermann

SEARCHLIGHT PARTNERS 28052 Camino Capistrano, Suite 209 Laguna Niguel, CA 92677 (949)429-8813 • [email protected]

Paint & Coatings Industry Executive Search Recruitment & Org. Consulting

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Contact Nicola James [email protected]

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CONSULTING AND TESTING

CUSTOM MANUFACTURING

Siva Microbiological Solutions LLC

Toll Converting & Packaging

www.sivams.com

• ISO 9001:2008, FDA-EPA-ATF Reg. Facility • 2 plants in N. Texas • Epoxy, urethane, solvent, water-based • High speed dispersion, vacuum processing • Adductions, advancements, prepolymer • Small, medium and large batch • Packaging: tankwagon, totes, drums, pails, gallons, quarts, pints and smaller

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AD INDEX Advanced Polymer Solutions . . . . . . . . . . 48

Conn and Co. . . . . . . . . . . . . . . . . . . . . . . . . 12

HOCKMEYER . . . . . . . . . . . . . . . . . . . . . . . .64

Reichhold. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

www.advancedpolymersolutions.com

www.connblade.com

www.hockmeyer.com

www.Reichhold.com

Acme-Hardesty Co.. . . . . . . . . . . . . . . . . . . 45

CPS Color. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ISP Performance Chemicals . . . . . . . . . . . 45

Reitech Corporation . . . . . . . . . . . . . . . . . . 32

www.acme-hardesty.com

www.cpscolor.com

www.ispcoatings.com/water

www.reitechcorporation.com

Cytec Industries Inc.. . . . . . . . . . . . . . 30, 45

Jiangxi Tikon Titanium . . . . . . . . . . . . . . . 4

Reynolds Industries . . . . . . . . . . . . . . . . . . 18

www.cytec.com

www.tikon.com.cn

www.reynoldsmixers.com

DeFelsko Corp. . . . . . . . . . . . . . . . . . . . . . . . 20

Jyoti Ceramic Industries . . . . . . . . . . . . . . . 3

Rhodia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

www.defelsko.com

www.jyoticeramic.com

www.rhodia.com

E.W. Kaufmann Company. . . . . . . . . . . . . 38

KW Container . . . . . . . . . . . . . . . . . . . . . . . . 2

Rio Tinto Minerals . . . . . . . . . . . . . . . . . . . 21

www.kwcontainer.com

www.riotintominerals.com

LANXESS Corporation. . . . . . . . . . . . . . . . 43

Ross, Charles & Son. . . . . . . . . . . . . . . . . . . 55

www.mpp.us.lanxess.com

www.mixers.com

Mason Color Works, Inc. . . . . . . . . . . . . . . 61

Siltech Corporation. . . . . . . . . . . . . . . . . . . 34

www.masoncolorpigments.com

www.siltechcorp.com

Mitsubishi Gas Chemical America, Inc. 33

Troy Corporation. . . . . . . . . . . . . . . . . . . . . 17

www.aromaticchemicals.com

www.troycorp.com

MYERS Engineering, Inc. . . . . . . . . . . . . .64

Unimin Corp. . . . . . . . . . . . . . . . . . . . . . . . . 26

www.myersmixer.com

www.BrilliantAdditions.com

Munzing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Univar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

www.munzing.com

www.univarcorp.com

Nexeo Solutions, LLC . . . . . . . . . . . . . . . . . 57

Wacker Chemical Corporation. . . . . . . . . 71

Air Products . . . . . . . . . . . . . . . . . . . . . 16, 27 www.airproducts.com/defoamer

AllCoat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 www.allcoattech.com

Arch Chemicals . . . . . . . . . . . . . . . . . . . . . . 65 www.archbiocides.com/proxelbzplus

Arkema Emulsion Systems . . . . . . . . .22-23 www.arkemacoatingresins.com

Asia Pacific Coatings Show 2011 . . . . . . 69 www.coatingsgroup.com

Brenntag North America . . . . . . . . . . . . . . 7 www.brenntagnorthamerica.com

Bway Corporation . . . . . . . . . . . . . . . . . . . . 49 www.bwaycorp.com/less-waste

BYK USA Inc. . . . . . . . . . . . . . . . . . . . . 19, 45

www.ewkaufmann.com

Elcometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 www.elcometer.com

Elementis . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 www.elementis.com

EMD Chemicals Inc. . . . . . . . . . . . . . . . . . . 45 www.emdchemicals.com

Emerald Performance Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

www.byk.com

www.emeraldmaterials.com

CINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

www.cinic.com

www.EMImills.com

www.nexeosolutions.com

www.wacker.com/knows-solutions

Classifier Milling Systems . . . . . . . . . . . . . 28

Evonik Degussa . . . . . . . . . . . . . . . . . . . . . . 13

Nubiola. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Wilden Pump Solutions . . . . . . . . . . . . . . . 10

www.cms-can.com

www.evonik.com/colotrend

www.nubiola.com

www.wildenpump.com

Coatings Trends & Technologies . . 25, 66-67

Heubach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pan Technology, Inc. . . . . . . . . . . . . . . . . . 45

Yuron Chemical Industry . . . . . . . . . . . . . 53

www.coatingsconference.com

www.heubachcolor.com

www.pantechnology.com

www.yulongchem.com

Visit ads.pcimag.com 70

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JULY 2011 | W W W . P C I M A G . C O M

CREATING TOMORROW’S SOLUTIONS

YOU KNOW US. YOU JUST DIDN’T KNOW IT.

To learn more about our customized solutions, visit us at www.wacker.com/knows-solutions T Or simply use your smart phone to scan the QR code above. Wacker Chemical Corporation, 3301 Sutton Road, Adrian, MI 49221, USA TEL: +1 888 922 5374, FAX: +1 517 264 4068, [email protected]

Relentlessly working for YOUR perfect solution

Münzing. Solving your foam issues by providing the broadest range of defoamer chemistries and unlimited technical assistance to the coatings and printing ink industry. While we may deal in complex science, what we do is very simple. We make your job easier. By conducting unlimited, rigorous testing with the broadest range of defoamer chemistries, we’ll develop precisely the defoaming additive that solves your problem. It’s this kind of unyielding commitment to the needs of coating and printing ink formulators everywhere that has gotten us to where we are today. Practically on speed dial at some of the largest, and smallest, coating and printing ink R&D labs around the world.

The Industry Standard in Defoamers DEE FO® XRM-1537A DEE FO® XRM-1547A DEE FO® 3010E/50 DEE FO® 97-3 DEE FO® PI-12

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AGITAN® 299 AGITAN® 350 AGITAN® 760 AGITAN® 771

To try our AGITAN and DEE FO defoamers and take advantage of our unlimited technical service, call

1-800-524-0055

www.munzing.com I [email protected]